Method for manufacturing laminated iron core, laminated iron core, and motor

Abstract

The present invention provides a method for manufacturing a laminated iron core, a laminated iron core, and a motor, the method comprising: a punching step of punching a plate-shaped steel plate to form an iron core sheet forming member having a back yoke portion extending in one direction and a plurality of tooth portions; a lamination step in which the core sheet forming member is deformed toward one side in the width direction and wound in a spiral shape, and the back yoke portion and the tooth portion are laminated so as to overlap each other in the axial direction; a first cutting step of cutting the iron core sheet forming member in the width direction at a position separated from the winding start end portion of the iron core sheet forming member by a first distance in the winding direction, the iron core sheet forming member being stacked in the axial direction when viewed in the axial direction, thereby forming a winding end portion on the iron core sheet forming member; and a second cutting step for cutting the core piece forming member in the width direction at a position overlapping with the winding start end portion when viewed in the axial direction, thereby forming the winding start end portion of the core piece forming member which is wound in a spiral shape next.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a laminated iron core, a laminated iron core, and a motor. Background Technology

[0002] A manufacturing method for producing a laminated iron core is known by forming a strip-shaped iron chip component by simultaneously deforming and winding it in a spiral shape. For example, as a manufacturing method described above, a method for manufacturing the laminated iron core using a laminated core manufacturing apparatus is disclosed. This apparatus includes: a forming section for feeding and forming a sheet to be processed; a winding section for winding the sheet processed by the forming section; and a cutting section for cutting the wound sheet at a predetermined position (e.g., Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2008-35598 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] Furthermore, the laminated iron core, made of laminated steel plates, has multiple connecting portions that connect the laminated steel plates in the lamination direction. Additionally, the laminated iron core, formed from an iron chip forming member that is spirally deformed and wound, has the aforementioned connecting portions near the aforementioned ends to prevent the ends of the iron chip forming member in the extending direction from curling up.

[0008] Preferably, the aforementioned connecting portions are arranged as evenly as possible in the circumferential direction. Therefore, in the aforementioned laminated iron core, it is preferable that the circumferential positions of the starting and ending ends of the winding of the ferrite forming member are separated in the circumferential direction. In this case, the position of the starting end of the winding of the ferrite forming member varies for each manufactured laminated iron core. Therefore, in subsequent processes during manufacturing, it is necessary to align the starting ends of the winding for each laminated iron core, reducing the manufacturing efficiency of the laminated iron core.

[0009] The purpose of this invention is to provide a manufacturing method that can improve the manufacturing efficiency of a cylindrical stacked iron core formed by deforming a strip-shaped iron chip forming component while spirally winding it.

[0010] Solution for solving the problem

[0011] One embodiment of the present invention discloses a method for manufacturing a stacked iron core by deforming an iron chip forming member that extends in a strip shape in one direction in a width direction while spirally winding it, thereby manufacturing a cylindrical stacked iron core that extends in the axial direction. The method for manufacturing the laminated iron core includes: a punching step, in which a plate-shaped steel plate is punched to form the aforementioned iron chip forming component, the iron chip forming component having a plate-shaped back yoke extending in one direction and a plurality of teeth extending from one side of the back yoke in the width direction to the other side of the width direction; a lamination step, in which the iron chip forming component is deformed to the side of the width direction and wound in a spiral shape, and the back yoke and the teeth are respectively overlapped in the axial direction; a first cutting step, in which the iron chip forming component is cut along the width direction at a position where, when viewed along the axial direction, the iron chip forming component is separated from the winding start end of the iron chip forming component by a first distance behind in the winding direction, thereby forming a winding end end of the iron chip forming component; and a second cutting step, in which the iron chip forming component is cut along the width direction at a position that overlaps with the winding start end when viewed along the axial direction, thereby forming the winding start end of the iron chip forming component that will be wound in a spiral shape next.

[0012] In one embodiment of the present invention, the laminated iron core is cylindrical. Iron chips having a plate-shaped back yoke extending in a spiral shape around a central axis and a plurality of teeth protruding radially inward from the back yoke are stacked in a state where the back yoke and the teeth overlap in the thickness direction, and extend axially. The iron chips have a side end formed by cutting off one end in the extension direction and another side end formed by cutting off the other end in the extension direction. The laminated iron core has a portion between the one side end and the other side end in a direction opposite to the first direction from the one side end of the iron chip toward the other side end when viewed along the axial direction. This portion has one fewer layer of iron chips between the two sides.

[0013] A motor according to one embodiment of the present invention has: a stator having the aforementioned laminated iron core and a coil wound on the aforementioned laminated iron core; and a rotor disposed radially inward relative to the aforementioned stator.

[0014] Invention Effects

[0015] According to the present invention, a manufacturing method is provided that can improve the manufacturing efficiency of a cylindrical stacked iron core formed by deforming a strip-shaped iron chip forming component while spirally winding it. Attached Figure Description

[0016] Figure 1 This is a perspective view showing the schematic structure of the stacked iron core in Embodiment 1.

[0017] Figure 2 It is a top view of the stacked iron core.

[0018] Figure 3 It is a diagram illustrating the general structure of an iron chip.

[0019] Figure 4 It is a blanking drawing of a steel plate.

[0020] Figure 5 This is a top view of the iron chip forming component.

[0021] Figure 6 This diagram shows the state of the iron chip forming component before it is bent into an arc shape.

[0022] Figure 7 This diagram shows the state of bending the iron chip forming component into an arc shape.

[0023] Figure 8 This diagram shows the state in which the iron chip forming component is wound into a spiral shape.

[0024] Figure 9 This is a diagram illustrating the first cutting process.

[0025] Figure 10 This is a diagram illustrating the second cutting process.

[0026] Figure 11 This is a diagram illustrating the joining process.

[0027] In the picture:

[0028] 1—Layered iron core, 1a—Part with one less sheet in the stack, 2—Iron chip, 2a—One side end, 2b—The other side end, 3—Connecting part, 3a—First connecting part, 3b—Second connecting part, 4—Circumferential positioning part, 11—Back yoke, 12—Tooth, 21—Back yoke part, 22, 22a, 22b—Toothed parts, 80—Steel plate, 81

[0029] —Iron chip forming component, 81a—winding start end, 81b—winding end end, 83—recess, 83a—first recess, 83b—second recess, CT1—position, CT2—position, L1—first distance, T1

[0030] — Winding fixture, T2— Welding device, R1— Range of the portion where the number of stacked iron cores is one less, R2— Iron core area, P— Central axis of stacked iron cores, Q— Central axis of winding fixture. Detailed Implementation

[0031] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Furthermore, the same or equivalent parts in the drawings are labeled with the same symbols, and their descriptions will not be repeated. Additionally, the dimensions of the constituent parts in the drawings do not faithfully represent the actual dimensions of the constituent parts or the dimensional ratios of each constituent part.

[0032] In the following description, the direction parallel to the central axis P of the laminated iron core 1 is called the axial direction, the direction orthogonal to the central axis P is called the radial direction, and the direction along the arc centered on the central axis P is called the circumferential direction. Furthermore, the direction within the circumferential direction from one end 2a of the iron chip 2 towards the other end 2b is designated as the first direction, and its opposite direction as the second direction. However, this definition is not intended to limit the orientation of the laminated iron core 1 used in this invention. In addition, in the figures, A represents the axial direction, and C represents the circumferential direction. Furthermore, C1 represents the first direction within the circumferential direction, and C2 represents the second direction within the circumferential direction.

[0033] Furthermore, in the following explanation, terms such as "fixed," "connected," "joined," and "installed" include not only cases where components are directly fixed to each other, but also cases where they are fixed via other components. That is, in the following explanation, terms such as "fixed" include both direct and indirect fixing of components to each other.

[0034] (Structure of stacked iron core)

[0035] Reference Figures 1 to 3 An example of the laminated iron core 1 in the embodiment will be described. The laminated iron core 1 is, for example, the stator core of a motor. The motor described above, for example, has: a stator having the laminated iron core 1 and a coil wound on the laminated iron core 1; and a rotor disposed radially inward relative to the stator. The structure of the motor is the same as that of a conventional motor, so the description is omitted.

[0036] Figure 1 This is a three-dimensional diagram showing the general structure of the stacked iron core 1. Figure 2 This is a top view of the laminated iron core 1. Figure 2 In the illustration, for ease of explanation, the two ends of the iron chip 2 in the extension direction are shown separated from the adjacent portions in the stacking direction. Figure 3 This is a diagram illustrating the general structure of iron chip 2.

[0037] like Figure 1As shown, the laminated iron core 1 extends axially along axis A with central axis P as its center. The laminated iron core 1 has a back yoke 11 and a plurality of teeth 12. The back yoke 11 is a cylindrical shape extending axially along axis A with central axis P as its center. The plurality of teeth 12 extend radially inward from the end face of the inner circumferential side of the back yoke 11. The plurality of teeth 12 are arranged circumferentially C. A coil (not shown) is wound around the plurality of teeth 12. In this embodiment, the laminated iron core 1 has 36 teeth 12. In addition, the laminated iron core may have more than 36 teeth or less than 36 teeth.

[0038] The main body of the laminated iron core 1 is formed by a plate-shaped iron chip 2 that is spirally wound around a central axis P and stacked along the axial direction A. The laminated iron core 1 has multiple connecting parts 3 and circumferential positioning parts 4.

[0039] like Figure 3 As shown, the iron chip 2 extends in a spiral shape with the central axis P as the center. Figure 1 and Figure 2 As shown, the iron chip 2 has one end portion 2a located at one end in the extending direction and another end portion 2b located at the other end in the extending direction. Figure 1 and Figure 2 In the middle, one end 2a is positioned below.

[0040] The iron chip 2 has a plate-shaped back yoke 21 and a plurality of plate-shaped teeth 22. The back yoke 21 extends in a spiral shape about a central axis P. The plurality of teeth 22 extend radially inward from the end face of the inner circumferential side of the back yoke 21. The plurality of teeth 22 are arranged circumferentially C.

[0041] The iron core 2 is stacked with the back yoke portion 21 and the tooth portion 22 overlapping each other in the thickness direction. The back yoke portion 21 stacked in the thickness direction constitutes the back yoke 11 of the stacked iron core 1. The multiple tooth portions 22 stacked in the thickness direction constitute the tooth 12 of the stacked iron core 1.

[0042] A sheet of electromagnetic steel, which serves as the material for the iron chip 2, is punched to form a strip-shaped iron chip forming component 81. The iron chip forming component 81 is then spirally wound in the thickness direction to form the iron chip 2. One end 2a and the other end 2b of the iron chip 2 are formed by cutting the strip-shaped iron chip forming component 81 at predetermined positions. In this embodiment, one end 2a is the starting end 81a when the iron chip forming component 81 is spirally wound, and the other end 2b is the ending end 81b when the iron chip forming component 81 is spirally wound. Details of the manufacturing method of the laminated iron core 1 will be described later.

[0043] The circumferential positions of one end 2a and the other end 2b of the iron chip 2 are different. Therefore, there is a portion 1a of the iron chip 2 with one fewer sheet of stacked sheets between one end 2a and the other end 2b in the second direction C2. The second direction C2 is the opposite direction to the first direction C1 from one end 2a to the other end 2b of the iron chip 2. Figure 1 and Figure 2 In the diagram, R1 represents the range of 1a where the number of stacked sheets of iron chip 2 is one less than the number of sheets.

[0044] In this embodiment, such as Figure 2 As shown, in the laminated iron core 1, the portion 1a of the iron chip 2 with one less stacked sheet is smaller than the other portions. That is, the central angle D of the portion 1a of the iron chip 2 with one less stacked sheet is less than 180 degrees. Therefore, a laminated iron core 1 with a shorter axial length A can be obtained.

[0045] Multiple connecting portions 3 extend along the stacking direction on the radially outer end faces of the laminated iron core 1. The multiple connecting portions 3 connect the back yoke portion 21 in the stacking direction. The multiple connecting portions 3 are obtained by joining the radially outer sides of the iron chip 2 in the stacking direction. For example, the multiple connecting portions 3 are obtained by welding the radially outer sides of the iron chip 2 along the axial direction A, etc. Furthermore, the iron chip may also have a recess extending along the stacking direction at the location where the connecting portions 3 are formed on the radially outer end face of the iron chip. In this case, the connecting portions may also be obtained by welding along the aforementioned recesses, etc.

[0046] In this embodiment, the laminated iron core 1 has six connecting portions 3. Viewed from the axial direction A, one of the six connecting portions 3, the first connecting portion 3a, is located radially outward relative to the tooth 22a of the iron chip 2 closest to one side end 2a. Viewed from the axial direction A, another of the six connecting portions 3, the second connecting portion 3b, is located radially outward relative to the tooth 22b of the iron chip 2 closest to the other side end 2b.

[0047] That is, the plurality of connecting portions 3 include: a first connecting portion 3a, wherein the tooth 22a of the portion closest to the side end 2a of the iron chip 2 is located on the radially outer end face; and a second connecting portion 3b, wherein the tooth 22b of the portion closest to the other side end 2b of the iron chip 2 is located on the radially outer end face.

[0048] Thus, a stacked iron core 1 can be obtained in which the position of one end near the extension direction of the iron chip 2 and the position of the other end near the extension direction of the iron chip 2 are joined in the stacking direction.

[0049] In this embodiment, the laminated iron core 1 has at least three connecting portions 3 arranged along the circumferential direction C. The second connecting portion 3b is adjacent to the first connecting portion 3a in the second direction C2.

[0050] The second connecting portion 3b has its toothed portion 22b, which is closest to the other end 2b of the iron chip 2, located on its radially outer end face. The first connecting portion 3a has its toothed portion 22a, which is closest to the other end 2a of the iron chip 2, located on its radially outer end face. As described above, the iron chip 2 has a portion 1a between one end 2a and the other end 2b in the second direction C2, which has one less sheet of the iron chip 2 in terms of the number of stacked sheets.

[0051] Therefore, the structure described above can reduce the number of sheets in the portion 1a that is one sheet shorter. As a result, a smaller laminated core 1 with a shorter length along the axial direction A can be obtained.

[0052] The circumferential positioning portion 4 extends along the stacking direction on the radially outer end face of the stacked iron core 1. The circumferential positioning portion 4 positions the stacked iron core 1 in the circumferential direction. In this embodiment, the circumferential positioning portion 4 is a recess. For example, by inserting a protrusion provided on a mounting platform for arranging the stacked iron core 1 into the recess, the stacked iron core 1 can be positioned relative to the mounting platform in the circumferential direction.

[0053] In this embodiment, the circumferential positions of one end 2a and the other end 2b of the iron chip 2 are determined based on the circumferential position of the circumferential positioning part 4. Therefore, in all the stacked iron cores 1 manufactured by the manufacturing method of the stacked iron core 1 described later, the positions of one end 2a and the other end 2b relative to the circumferential positioning part 4 are the same when viewed along the axial direction A.

[0054] (Manufacturing method of laminated iron core)

[0055] Next, refer to Figures 4 to 11 An exemplary manufacturing method for a laminated iron core 1 having the above-described structure will be described. Figure 4 This is an example of a punching drawing for steel plate 80. Figure 5 This is a top view of the iron chip forming component 81. Figures 6 to 8 This is a diagram illustrating the lamination process. Figure 9 This is a diagram illustrating the first cutting process. Figure 10 This is a diagram illustrating the second cutting process. Figure 11 This is a diagram illustrating the joining process.

[0056] For ease of explanation, the region in the iron chip forming member 81 bounded by adjacent teeth 22 in the circumferential direction will be referred to as the iron chip region R2. In the figures, the iron chip region R2 located at the winding start end 81a of the iron chip forming member 81 is shown as 1, and is indicated by ascending numbers along the winding direction W. Furthermore, adjacent iron chip regions R2 in the stacked core 1 in the stacking direction are labeled with the same number.

[0057] The method for manufacturing the laminated iron core 1 is to deform an iron chip forming member 81 that extends in a strip shape in one direction while being spirally wound in one direction, thereby manufacturing a cylindrical laminated iron core 1 that extends along the axial direction with the central axis P as the center.

[0058] Specifically, the manufacturing method of the laminated iron core 1 includes a punching process, a lamination process, a first cutting process, a second cutting process, and a joining process.

[0059] In the blanking process, a strip of steel sheet 80, which is a magnetic material, is blanked to form a strip of iron chip forming component 81. The blanking process is performed by stamping. Detailed description of the stamping process is omitted.

[0060] In the blanking process, a punch is used to... Figure 4 The area marked with diagonal lines is punched to form an iron chip forming component 81, which has a back yoke portion 21, multiple teeth 22, multiple recesses 83, and a circumferential positioning portion 4. The iron chip forming component 81 is part of the iron chip 2 that becomes the laminated iron core 1. The multiple recesses 83 are part of the connecting portion 3 that becomes the laminated iron core 1.

[0061] like Figure 5 As shown, the back yoke portion 21 formed by the punching process is a strip extending along the length direction of the steel plate 80. Multiple teeth 22 extend from one side of the back yoke portion 21 in the width direction. Furthermore, the width direction of the back yoke portion 21 intersects the aforementioned length direction.

[0062] The iron chip forming component 81 formed by the punching process includes multiple iron chip forming components 81-1, 81-2...81-n, which respectively become iron chips 2 of the stacked iron core 1. Details will be described later, but the iron chip forming component 81 formed by the punching process is cut off at the winding start end 81a and the winding end end 81b of the iron chip forming component 81 formed by the punching process, thereby forming an iron chip forming component 81 that becomes an iron chip 2.

[0063] One end of the iron chip forming member 81 formed by the punching process along its length becomes the winding start end 81a of the iron chip forming member 81. In this embodiment, the winding start end 81a of the iron chip forming member 81 becomes one end 2a of the iron chip 2 in the stacked iron core 1.

[0064] Multiple recesses 83 are located at the end of the back yoke portion 21 on the other side of its width direction. In this embodiment, multiple recesses 83 are located in the first iron chip region R2 closest to the winding start end 81a of the iron chip forming member 81 and in six separate iron chip regions R2 arranged in the winding direction W starting from the first iron chip region R2.

[0065] Specifically, in this embodiment, a recess 83 is formed in each of the following iron chip regions: No. 1 (R2), No. 7 (R2), No. 13 (R2), No. 19 (R2), No. 25 (R2), and No. 31 (R2). However, the number and location of the recesses are not limited to this. Preferably, the recesses are evenly spaced in the winding direction W. Preferably, the number of recesses is three or more between the first iron chip region R2 and the next first iron chip region R2.

[0066] The first recess 83a, which is formed in the iron chip region R2, is located on the other side of the width direction of the back yoke 21 relative to the tooth 22a, which is located closest to the iron chip forming member 81 and is the starting end 81a of the winding.

[0067] In this embodiment, a second recess 83b is formed in the 31st iron chip region R2, adjacent to the first recess 83a rearward in the winding direction W. The front boundary of the 31st iron chip region R2 in the winding direction W is the winding end 81b of the iron chip forming member 81. That is, the recess 83 formed in the 31st iron chip region R2 is located on the other side of the width direction of the back yoke 21, relative to the tooth 22b closest to the iron chip forming member 81, which is the winding end 81b.

[0068] In this embodiment, a plurality of recesses 83 are formed in every six separately arranged iron chip regions R2. Therefore, in the iron chip forming member 81 wound into a spiral shape, the central angle of adjacent recesses 83 in the circumferential direction is 60 degrees.

[0069] In the lamination process, the iron chip forming component 81 is deformed in the width direction while being spirally wound, and the back yoke portion 21 and the tooth portion 22 are overlapped in the axial direction A.

[0070] Specifically, such as Figure 6 As shown, the end face of the radially inner side of the tooth 22a of the winding start end 81a closest to the iron chip forming member 81 contacts the outer peripheral surface of the columnar winding jig T1 that extends along the central axis Q in the axial direction A.

[0071] Next, as Figure 7 and Figure 8As shown, the iron chip forming component 81 is wound around the outer peripheral surface of the winding fixture T1. Furthermore, in the lamination process, iron chip regions R2 with the same number are overlapped in the thickness direction. Thus, an iron chip forming component 81 is formed by laminating a back yoke portion 21 extending spirally around the central axis Q and a plurality of teeth 22 extending radially inward, respectively, in a state of overlap in the thickness direction.

[0072] In the first cutting process, a winding end 81b is formed on the iron chip forming component 81. Specifically, as follows: Figure 9 As shown, at position CT1, the iron chip forming component 81, which is stacked in the axial direction A, is cut off along the width direction. Position CT1 is the position where the iron chip forming component 81 is separated by a first distance L1 relative to the winding start end 81a of the iron chip forming component 81 in the winding direction W. Thus, the iron chip forming component 81-1, which is an iron chip 2 of a stacked iron core 1, is formed. Furthermore, the winding end 81b formed by the first cutting process becomes the other end 2b of the iron chip 2 of the stacked iron core 1.

[0073] The spiral-shaped iron chip forming component 81-1 has a portion between the position of the winding end 81b and the position of the winding start end 81a in the winding direction W, which has one less sheet of steel plate 80. This portion becomes the portion 1a with one less sheet of iron chip 2.

[0074] In this embodiment, viewed from the axial direction A, position CT1 is a position where the central angle D is less than 180 degrees from the position of the winding start end 81a. Specifically, in this embodiment, position CT1 is the boundary between iron chip region R2 of No. 31 and iron chip region R2 of which the second recess 83b is formed.

[0075] In the second cutting process, the winding start end 81a of the iron chip forming component 81-2, which will subsequently be wound in a spiral shape, is formed. Specifically, as... Figure 10 As shown, in the second cutting process, at position CT2 where the winding start end 81a of the previously formed iron chip forming component 81-1 overlaps when viewed along the axial direction A, the iron chip forming component 81 is cut off along the width direction. This forms the winding start end 81a of the iron chip forming component 81-2, which is subsequently wound in a spiral shape. Furthermore, the winding start end 81a formed by the second cutting process becomes one side end 2a of the iron chip 2 of the laminated iron core 1.

[0076] Therefore, in all the stacked iron cores 1 manufactured by the manufacturing method of stacked iron core 1, the circumferential position of the winding start end 81a, the circumferential position of the winding end 81b, and the circumferential position of the plurality of recesses 83 are consistent.

[0077] In the bonding process, the back yoke portion 21 of the iron chip forming component 81, which is stacked in the axial direction A by the lamination process, is bonded in the lamination direction, thereby connecting them.

[0078] Specifically, the back yoke portion 21 is welded in the stacking direction at the locations of the plurality of recesses 83. Furthermore, the method of joining the back yoke portions in the stacking direction is not limited to a specific method. For example, as... Figure 11 As shown, the back yoke portion can be joined in the stacking direction using a welding device T2 arranged radially outward relative to the plurality of recesses 83. For example, the iron chip forming component can also be rotated about a central axis to sequentially position the plurality of recesses at the welding positions of the welding device T2, thereby joining the back yoke portion in the stacking direction.

[0079] Through the above processes, the laminated iron core 1 is manufactured.

[0080] As explained above, the exemplary method for manufacturing the laminated iron core 1 of this embodiment is a method for manufacturing a cylindrical laminated iron core 1 extending in the axial direction by spirally winding an iron chip forming member 81 that extends in a strip shape in one direction while deforming it in the width direction. The method for manufacturing the laminated iron core 1 includes a punching process, a lamination process, a first cutting process, and a second cutting process.

[0081] The blanking process forms a ferrite chip forming component 81 by blanking a plate-shaped steel plate 80. The ferrite chip forming component 81 has a plate-shaped back yoke portion 21 extending in one direction and a plurality of teeth 22 extending from one side of the back yoke portion 21 in the width direction to the other side of the width direction. In the lamination process, the ferrite chip forming component 81 is deformed in the width direction while being spirally wound, and the back yoke portion 21 and the teeth 22 are overlapped and laminated in the axial direction A.

[0082] In the first cutting process, at position CT1, where the stacked iron chip forming component 81 is separated from the winding start end 81a of the iron chip forming component 81 by a first distance L1 in the winding direction W, the iron chip forming component 81 is cut along the width direction, thereby forming a winding end end 81b on the iron chip forming component 81. In the second cutting process, at position CT2, which overlaps with the winding start end 81a, the iron chip forming component 81 is cut along the width direction, thereby forming the winding start end 81a of the iron chip forming component 81 that will be wound in a spiral shape next.

[0083] In this manufacturing method, the positions of the winding start end 81a and the winding end end 81b of all the ferrite core forming members 81 in the manufactured laminated iron cores 1 can be made identical. Therefore, for example, in processes such as joining the winding start end 81a and the winding end end 81b, the winding start end 81a and the winding end end 81b can be easily positioned at the joining position. That is, for workbenches and equipment used in subsequent processes, it is not necessary to adjust the positions of the winding start end 81a and the winding end end 81b for each ferrite core forming member 81. Therefore, the manufacturing efficiency of the laminated iron core 1 can be improved.

[0084] Furthermore, the positions of the winding start end 81a and the winding end end 81b are consistent in all the laminated iron cores 1 manufactured by this method. Therefore, for example, when manufacturing a motor having laminated iron cores 1, it is not necessary to adjust the circumferential position for each laminated iron core 1 using the equipment used to manufacture such motors. Therefore, by using the above-described manufacturing method to manufacture laminated iron cores 1, the manufacturing efficiency of motors having laminated iron cores 1 can be improved.

[0085] In this embodiment, during the first cutting process, the iron chip forming component 81 is cut along the width direction at a position CT1 with a center angle of less than 180 degrees from the position of the winding start end 81a relative to the rear of the winding direction W relative to the winding start end 81a.

[0086] This manufacturing method enables the production of a laminated iron core 1 in which the winding end 81b, viewed from the axial direction A, is located at a position with a rear center angle of less than 180 degrees from the winding start end 81a toward the winding direction W.

[0087] The steel plate 80 between the winding end 81b of one iron chip forming component 81 and the winding start 81a of the next iron chip forming component 81 becomes scrap material. Therefore, in the above manufacturing method, compared to the case where the winding end 81b is located at a position more than 180 degrees away from the center angle from the winding start 81a in the winding direction W when viewed along the axial direction A, scrap material can be reduced. As a result, the product yield relative to material yield can be improved.

[0088] In this embodiment, the manufacturing method of the laminated iron core 1 further includes a joining step in which the back yoke portion 21 of the iron chip forming member 81, which is laminated in the axial direction A by the lamination process, is joined in the lamination direction. Furthermore, in the punching step, for the tooth portion 22a closest to the iron chip forming member 81, which becomes the winding start end 81a, a first recess 83a is formed at the end of the back yoke portion 21 on the other side of the aforementioned width direction; and for the tooth portion 22b closest to the iron chip forming member 81, which becomes the winding end end 81b, a second recess 83b is formed at the end of the back yoke portion 21 on the other side of the aforementioned width direction. In the joining step, the back yoke portion 21 of the iron chip forming member 81, which is laminated in the axial direction A by the lamination process, is joined along the lamination direction at the positions of the first recess 83a and the second recess 83b.

[0089] Thus, an iron chip forming member 81 can be formed having a first recess 83a near the winding start end 81a and a second recess 83b near the winding end end 81b. The iron chip forming member 81 is joined at the first recess 83a and the second recess 83b in the stacking direction. Therefore, a stacked iron core 1 can be obtained that is joined in the stacking direction near the winding start end 81a and near the winding end end 81b.

[0090] Therefore, for example, it is unnecessary to cut the portion between the joint and the winding start end 81a and the portion between the joint and the winding end end 81b in the iron chip forming member 81, or to fix the aforementioned portions to the portions of the iron chip forming member 81 that overlap in the stacking direction. As a result, the manufacturing efficiency of the stacked iron core 1 can be improved.

[0091] Furthermore, the laminated iron core 1 manufactured by the above-described manufacturing method is a cylindrical laminated iron core 1 in which iron chips 2 are stacked in a state where the back yoke portion 21 and the tooth portion 22 are respectively overlapped in the thickness direction and extend along the axial direction A. The iron chip 2 has a plate-shaped back yoke portion 21 extending in a spiral shape with the central axis P as the center, and a plurality of teeth 22 protruding radially inward from the back yoke portion 21. The iron chip 2 has a side end 2a formed by cutting off one end in the extension direction and a side end 2b formed by cutting off the other end in the extension direction. The laminated iron core 1 has a portion 1a between the side end 2a and the other end 2b in a direction C2 opposite to the first direction C1 from the side end 2a to the other end 2b when viewed along the axial direction A, where the number of stacked iron chips 2 is one less.

[0092] The laminated iron core 1 having the above-described structure is manufactured by a method for manufacturing laminated iron core 1. In this manufacturing method, the positions of the winding start end 81a and the winding end end 81b of all the iron chip forming components 81 manufactured by this method can be made identical. Therefore, for example, in processes such as joining the winding start end 81a and the winding end end 81b, the winding start end 81a and the winding end end 81b can be easily positioned at the joining position. Therefore, the manufacturing efficiency of the laminated iron core 1 can be improved. Therefore, a laminated iron core 1 that can be manufactured by a manufacturing method with improved manufacturing efficiency can be obtained.

[0093] In the laminated iron core 1 manufactured by the above manufacturing method, the central angle D of the portion 1a of the iron chip 2 with one less sheet is less than 180 degrees.

[0094] By employing the manufacturing method described above, the amount of scrap material that becomes steel plate 80 can be reduced. Therefore, the yield rate of the product relative to the material can be improved. Thus, a laminated iron core 1 can be obtained through a manufacturing method that improves the yield rate.

[0095] The laminated iron core 1 manufactured by the above-described manufacturing method has a plurality of connecting portions 3 extending along the axial direction A on the radially outer end face and connecting the back yoke portion 21 in the lamination direction. The plurality of connecting portions 3 include: a first connecting portion 3a, wherein the tooth portion 22a of which is located on the radially outer end face relative to the end 2a of the iron chip 2; and a second connecting portion 3b, wherein the tooth portion 22b of which is located on the radially outer end face relative to the end 2b of the iron chip 2.

[0096] By employing a manufacturing method for the laminated iron core 1, multiple recesses 83 formed on the iron chip forming member 81 are welded along the axial direction A, thereby obtaining multiple connecting portions 3. The first connecting portion 3a has its tooth 22a located on its radially outer end face relative to the winding start end 81a closest to the iron chip forming member 81. The second connecting portion 3b has its tooth 22b located on its radially outer end face relative to the winding end end 81b closest to the iron chip forming member 81.

[0097] Therefore, when manufacturing the laminated iron core 1, the following steps are unnecessary: ​​cutting off the portion between the joint and the winding start end 81a, and the portion between the joint and the winding end end 81b in the iron chip forming member 81, or fixing the aforementioned portions to portions of the iron chip forming members 81 that overlap in the lamination direction. Therefore, the manufacturing efficiency of the laminated iron core 1 can be improved. Thus, a laminated iron core 1 that can be manufactured using a manufacturing method that improves manufacturing efficiency can be obtained.

[0098] Furthermore, the laminated iron core 1 has at least three connecting portions 3 arranged in the circumferential direction C of the laminated iron core 1. The second connecting portion 3b is adjacent to the first connecting portion 3a in the direction C2 opposite to the first direction C1.

[0099] Therefore, the portion 1a with one less sheet in the stack can be reduced. Therefore, a stacked core 1 with a smaller length in the axial direction A can be obtained. Therefore, a stacked core 1 with a smaller length in the axial direction A can be obtained by a manufacturing method that improves manufacturing efficiency.

[0100] Additionally, the exemplary motor of this embodiment has: a stator having a laminated iron core 1 and a coil wound on the laminated iron core 1; and a rotor disposed radially inward relative to the stator.

[0101] Therefore, a motor having a laminated iron core 1 that can be manufactured using a manufacturing method that improves manufacturing efficiency can be obtained. Furthermore, the positions of the winding start end 81a and winding end end 81b of all laminated iron cores 1 manufactured by the above-described manufacturing method are consistent. Therefore, in the process of manufacturing a motor having a laminated iron core 1, it is not necessary to adjust the circumferential position for each laminated iron core 1 using the equipment used to manufacture the motor. Therefore, the manufacturing efficiency of the motor can be improved. Thus, a motor that can be manufactured using a manufacturing method that improves manufacturing efficiency can be obtained.

[0102] (Other implementation methods)

[0103] The embodiments of the present invention have been described above, but the above embodiments are merely examples for implementing the present invention. Therefore, the invention is not limited to the above embodiments, and appropriate modifications can be made to the above embodiments without departing from their spirit.

[0104] In the above embodiment, the laminated iron core 1 is connected in the lamination direction by a connecting portion 3 extending in the lamination direction on the radially outer end face. However, the laminated iron core can also be connected in the lamination direction by other methods. For example, the laminated iron core can be connected in the lamination direction by a connecting portion extending in the lamination direction on the radially inner end face. Alternatively, the laminated iron core can be connected in the lamination direction by an adhesive applied between the overlapping areas of the iron chip in the lamination direction. Alternatively, the laminated iron core can be connected in the lamination direction by riveting in the axial direction.

[0105] In the above embodiment, the laminated iron core 1 has six connecting portions 3. However, the laminated iron core may have fewer than six connecting portions or more than six connecting portions. Preferably, the laminated iron core has at least three connecting portions. This ensures the connection strength of the laminated iron core in the stacking direction.

[0106] In the above embodiment, the second connecting portion 3b is adjacent to the first connecting portion 3a in the second direction C2. However, the second connecting portion may not be adjacent to the first connecting portion in the second direction. That is, other connecting portions may be arranged between the second connecting portion and the first connecting portion in the second direction.

[0107] In the above embodiment, the circumferential positioning part 4 is a recess. However, the circumferential positioning part may not be a recess. The circumferential positioning part only needs to have a structure that can be positioned circumferentially in the stacked iron core.

[0108] In the above embodiment, one end 2a of the iron chip 2 is formed by the second cutting step of the manufacturing method of the laminated iron core 1, and the other end 2b of the iron chip 2 is formed by the first cutting step of the manufacturing method of the laminated iron core 1. That is, in the above embodiment, one end 2a is the winding start end 81a of the iron chip forming member 81, and the other end 2b is the winding end 81b of the iron chip forming member 81. However, it is also possible that one end of the iron chip is formed by the first cutting step of the manufacturing method of the laminated iron core, and the other end of the iron chip is formed by the second cutting step of the manufacturing method of the laminated iron core. That is, it is also possible that one end is the winding end of the iron chip forming member, and the other end is the winding start end of the iron chip forming member.

[0109] In the lamination process of the above embodiment, the iron chip forming component 81 is wound around the outer peripheral surface of the winding jig T1. However, in the lamination process, the iron chip forming component can also be wound around the outer peripheral surface of the winding jig by rotating the winding jig, which rotates together with the iron chip forming component, in the opposite direction to the winding direction W.

[0110] (Structure Example)

[0111] In addition, this technology can also adopt the following structure.

[0112] (1) The method of manufacturing a laminated iron core is to deform an iron chip forming component that extends in a strip shape in one direction while being spirally wound in the width direction, thereby manufacturing a cylindrical laminated iron core that extends in the axial direction. The method for manufacturing the laminated iron core includes: a punching step, in which a plate-shaped steel plate is punched to form the aforementioned iron chip forming component, the iron chip forming component having a plate-shaped back yoke extending in one direction and a plurality of teeth extending from one side of the back yoke in the width direction to the other side of the width direction; a lamination step, in which the iron chip forming component is deformed to the side of the width direction and wound in a spiral shape, and the back yoke and the teeth are respectively overlapped in the axial direction; a first cutting step, in which the iron chip forming component is cut along the width direction at a position where, when viewed along the axial direction, the iron chip forming component is separated from the winding start end of the iron chip forming component by a first distance behind in the winding direction, thereby forming a winding end end of the iron chip forming component; and a second cutting step, in which the iron chip forming component is cut along the width direction at a position that overlaps with the winding start end when viewed along the axial direction, thereby forming the winding start end of the iron chip forming component that will be wound in a spiral shape next.

[0113] (2) According to the manufacturing method of the stacked iron core described in (1), in the first cutting process, the iron chip forming component is cut along the width direction at a position with a center angle of less than 180 degrees from the position of the winding start end relative to the winding start end of the iron chip forming component in the winding direction.

[0114] (3) The method for manufacturing a laminated iron core according to (1) or (2) further includes a joining step in which the back yoke portion of the iron chip forming member, which is laminated along the axial direction by the aforementioned lamination step, is joined in the lamination direction. In the aforementioned punching step, for the tooth portion closest to the iron chip forming member at the position that becomes the winding start end, a first recess is formed at the end of the back yoke portion on the other side of the width direction; for the tooth portion closest to the iron chip forming member at the position that becomes the winding end end, a second recess is formed at the end of the back yoke portion on the other side of the width direction. In the aforementioned joining step, the back yoke portion of the iron chip forming member, which is laminated along the axial direction by the aforementioned lamination step, is joined in the lamination direction at the positions of the first recess and the second recess.

[0115] (4) The laminated iron core is cylindrical, and iron chips having a plate-shaped back yoke extending in a spiral shape around a central axis and multiple teeth protruding radially inward from the back yoke are laminated in a state where the back yoke and the teeth overlap in the thickness direction, and extend axially. The iron chip has a side end formed by cutting off one end in the extension direction and another side end formed by cutting off the other end in the extension direction. The laminated iron core has a portion between the one side end and the other side end in a direction opposite to the first direction from the one side end of the iron chip toward the other side end when viewed along the axial direction. The number of laminated iron chips is one less than that of the first side end.

[0116] (5) According to the stacked iron core described in (4), the central angle of the portion of the stacked iron core with one less sheet is less than 180 degrees.

[0117] (6) The stacked iron core according to (4) or (5) has a plurality of connecting portions that extend axially on radially outer end faces and connect the back yoke portions in the stacking direction. The plurality of connecting portions include: a first connecting portion whose toothed portion relative to the end closest to the side of the iron chip is located on the radially outer end face; and a second connecting portion whose toothed portion relative to the end closest to the other side of the iron chip is located on the radially outer end face.

[0118] (7) The laminated iron core as described in (6) has at least three of the aforementioned connecting portions arranged circumferentially on the laminated iron core. The second connecting portion is adjacent to the first connecting portion in a direction opposite to the first direction.

[0119] (8) The motor has: a stator having a stacked iron core as described in any one of (4) to (7) and a coil wound on the stacked iron core; and a rotor disposed radially inward relative to the stator.

[0120] Production availability

[0121] The present invention can be applied to a method for manufacturing a laminated iron core having a back yoke extending linearly along the length direction of the electromagnetic steel sheet and a plurality of teeth extending along the width direction of the electromagnetic steel sheet by punching a strip-shaped electromagnetic steel sheet.

Claims

1. A manufacturing method of a laminated core that manufactures a cylindrical laminated core extending in an axial direction by deforming core piece forming members extending in a band shape in one direction toward one side in a width direction and winding in a spiral shape, the manufacturing method of a laminated core characterized by comprising: a blanking process of forming the core piece forming members having a back yoke portion extending in a plate shape in the one direction and a plurality of tooth portions extending from one side in the width direction of the back yoke portion toward the one side in the width direction by blanking a plate-shaped steel sheet; a laminating process of deforming the core piece forming members toward the one side in the width direction and winding in a spiral shape and laminating the back yoke portions and the tooth portions in the axial direction respectively in a superposed manner; a first cutting process of cutting the core piece forming members in the width direction at a position separated by a first distance in a winding direction from a winding start end portion of the core piece forming members with respect to the core piece forming members laminated in the axial direction as viewed in the axial direction, thereby forming a winding end portion in the core piece forming members; and a second cutting process of cutting the core piece forming members in the width direction at a position overlapping the winding start end portion as viewed in the axial direction, thereby forming the winding start end portion of the core piece forming members wound next in a spiral shape.

2. The manufacturing method of a laminated core according to claim 1, characterized in that in the first cutting process, the core piece forming members are cut in the width direction at a position separated by a first distance in a winding direction from a winding start end portion of the core piece forming members toward the rear in the winding direction as viewed in the axial direction, at a position from the winding start end portion at which a central angle is less than 180 degrees as viewed in the axial direction.

3. The manufacturing method of a laminated core according to claim 1 or 2, characterized in that further comprising a joining process of joining the back yoke portions of the core piece forming members laminated in the axial direction by the laminating process in a laminating direction, in the blanking process, a first recess portion is formed in an end portion on the other side in the width direction of the back yoke portion with respect to the tooth portion closest to a position of the core piece forming members that becomes the winding start end portion, a second recess portion is formed in an end portion on the other side in the width direction of the back yoke portion with respect to the tooth portion closest to a position of the core piece forming members that becomes the winding end portion, and in the joining process, the back yoke portions of the core piece forming members laminated in the axial direction by the laminating process are joined in the laminating direction at positions of the first recess portions and positions of the second recess portions.

4. A laminated core that is cylindrical and extends in an axial direction with core pieces having a back yoke portion extending in a spiral shape with a center axis as a center in a plate shape and a plurality of tooth portions protruding from the back yoke portion toward an inner side in a radial direction laminated in a state in which the back yoke portions and the tooth portions are superposed in a thickness direction respectively, the laminated core characterized by comprising: ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The core pieces have a one-side end portion formed by cutting at one end in an extending direction, and a other-side end portion formed by cutting at the other end in the extending direction, The laminated core has a portion with one less core piece between the one-side end portion and the other-side end portion in a direction opposite to a first direction from the one-side end portion toward the other-side end portion of the core pieces in the axial direction.

5. The laminated core according to claim 4, wherein The central angle of the portion with one less core piece is less than 180 degrees.

6. The laminated core according to claim 4, wherein The plurality of connecting portions include: a first connecting portion on a radially outer end surface with respect to the tooth portion closest to the one-side end portion of the core piece; and a second connecting portion on a radially outer end surface with respect to the tooth portion closest to the other-side end portion of the core piece.

7. The laminated core according to claim 6, wherein The plurality of connecting portions include: at least three connecting portions arranged in a circumferential direction of the laminated core, The second connecting portion is adjacent to the first connecting portion in a direction opposite to the first direction.

8. A motor characterized by The stator has the laminated core according to any one of claims 4 to 7 and a coil wound around the laminated core, and The rotor is disposed radially inward with respect to the stator. ​

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