Device and method for manufacturing sheets of a sheet metal stack of a power-generating component, as well as an electric rotary machine

Abstract

The invention relates to a device and a method for manufacturing sheets of a laminated core of a power-generating component. Furthermore, the present invention relates to an electric rotary machine.The device comprises a receiving unit (1) and, mechanically connected thereto, a punch (10) and a die (20), wherein a relative rotational movement (21) about the longitudinal axis (12) of the punch (10) is possible between the punch (10) and the die (20), and at least one positioning pin (22) on one of the two elements punch (10) and die (20), and at least one bushing (23) on or in the other of the two elements punch (10) and die (20), which are arranged and configured such that, when the punch (10) is in the correct angular relative position to the die (20), the positioning pin (22) can be inserted into the bushing (23), and when the punch (10) is in an incorrect angular relative position to the die (20), the positioning pin (22) can be inserted into the bushing (23). (23) to prevent and thus prevent the punch (10) from entering the die (20). The device and method proposed here provide solutions that enable a cost-effective and reliable permanent stamping process for sheet metal.

Description

[0001] The invention relates to a device and a method for producing laminations of a laminated core of a power-generating component. Furthermore, the present invention relates to an electric rotary machine.

[0002] It is known to manufacture the body of a power-generating component of an electrical rotating machine, such as the rotor or stator, from a laminated core. This laminated core comprises a large number of thin individual laminations. These individual laminations must be stacked. However, this requires the tools that punch the individual laminations to run at a very high frequency in order to produce the required number of individual laminations per unit of time. During punching, a punch moves into a correspondingly shaped die.

[0003] The problem here is that the individual sheets have tolerances with regard to their thicknesses as well as the parallelism of their surfaces. Even small tolerances in a sheet stack with a large number of individual sheets can cause unacceptable dimensional deviations in the produced sheet stack. In order to compensate for these tolerances, a known process is used in which the die, in which the individual punched sheets are collected in a sheet stack, is rotated around the longitudinal axis of the punch. The punching punch is not rotated. The rotation has to take place at a very high speed in order to be carried out between individual strokes of the punching process. With rotationally symmetrical sheets, this rotation can be carried out at almost any angle. The tolerances of the sheets no longer add up along the stacking direction in the sheet stack, but essentially cancel each other out.

[0004] However, with non-rotationally symmetrical sheets, the rotation of the die cannot be carried out at any angle, as otherwise collisions between the punch and the complementarily shaped die may occur.

[0005] Only rotations of the die in angular positions are possible in which the cross-sectional area of ​​the die or its recess is aligned symmetrically to a previous angular position of the die.

[0006] This angular position must be adjusted with corresponding precision. However, this angular position must be adjusted during punching operation, and therefore at very high speed, without causing a collision between the punch and die.

[0007] Based on this, the present invention is based on the object of providing a device and a method for producing sheets of a laminated core of a power-generating component of an electrical rotary machine, with which a permanent punching process of sheets is made possible in a cost-effective and reliable manner.

[0008] This object is achieved by the device for producing laminations of a laminated core of a power-generating component of an electrical rotary machine according to claim 1 and by the method for producing laminations of a laminated core of a power-generating component of an electrical rotary machine according to claim 8. Advantageous embodiments of the device are specified in subclaims 2 to 7. An advantageous embodiment of the method is specified in subclaim 9. In addition, an electrical rotary machine according to claim 10 is provided.

[0009] The features of the claims can be combined in any technically reasonable manner, whereby the explanations from the following description as well as features from the figures can also be used to comprise additional embodiments of the invention.

[0010] The invention relates to a device for producing laminations of a laminated core of a power-generating component, such as a stator of an electrical rotary machine, comprising a receiving device and a punch mechanically connected thereto, as well as a die, wherein a relative rotational movement about the longitudinal axis of the punch can be carried out between the punch and the die.Furthermore, the device comprises at least one positioning bolt on one of the two elements, punch and die, and at least one bushing on or in the other of the two elements, punch and die, which are arranged and configured in such a way that, when the angular relative position of the punch to the die is correct, the positioning bolt can be moved into the bushing, and when the angular relative position of the punch to the die is incorrect, the positioning bolt can be prevented from moving into the bushing and thus the punch to move into the die.

[0011] Depending on the unlocking situation, the punching punch can be fixed to the holding device along the longitudinal axis of the punching punch, with the longitudinal axis being aligned along the direction of movement of the punching punch.

[0012] An advantageous embodiment provides that the die is rotatable relative to the punching punch to produce a laminated core with differently aligned individual sheets, so that the sheet thickness tolerances and / or parallelism tolerances compensate for each other in the laminated core.

[0013] The positioning pin essentially takes the form of a pin or other projection that allows it to be inserted into a bushing with a substantially complementary cross-section. The bushing does not have to be an additional element on or in the die, but can also be implemented as a simple hole or recess in the die.

[0014] A correct angular relative position of the punch to the die is given if moving the punch into the die does not lead to a collision with the die.

[0015] This provides a mechanical protection device that protects the tool from damage in the event of an incorrect die angular position. The device can be designed such that the die has at least one blocking area on a radius on which the bushing is arranged, which can be used to block the retraction movement of the positioning pin into the die. The radius is an ideal radius on the die around the longitudinal axis of the punch on which the bushing is located. In one embodiment, at least one blocking area is formed directly next to the bushing.

[0016] This means that if the positioning pin cannot move into a bushing because the angular relative position of the punch to the die is not correct, the positioning pin hits a blocking area next to the bushing, which blocks the lowering of the positioning pin into the die and thus prevents the punch from moving into the die.

[0017] The positioning bolt can be mechanically connected to a first thrust element, which is also displaced when the retraction movement of the positioning bolt is blocked and the positioning bolt is displaced as a result, and thereby actuates an unlocking device in such a way that unlocks a fixation of the punching punch on the receiving device and enables a relative translation to be carried out between the receiving device and the punching punch, so that when the relative translation is carried out, a retraction of the punching punch into the die can be prevented when the receiving device moves towards the die.

[0018] Furthermore, the unlocking device can comprise at least one wedge element which, under the action of a first thrust force applied by the first thrust element, displaces a second thrust element using the principle of the inclined plane, wherein the second thrust element is configured to lock the unlocking device in a first position and to release the unlocking device in a second position.

[0019] In addition, the unlocking device can comprise a first wedge element as a component of the first pushing element, and a second wedge element as a component of the second pushing element, wherein inclined planes of the two wedge elements abut one another.

[0020] The unlocking device can comprise a ramp element, a support element and a release area, wherein the receiving device is supported on one of the two elements, ramp element and support element, and the punch is supported on the other of the two elements, ramp element and support element.The second pushing element is mechanically connected to one of the two elements, ramp element and support element, which is also displaceable driven by a second pushing force caused by the second pushing element, wherein in a locked situation of the unlocking device a plateau of the ramp element rests on the support element and thereby the relative position of the punching punch in relation to the receiving device along the direction of movement of the punching punch is fixed, and in an unlocked situation of the unlocking device the ramp element is located in the release area and thereby a relative translation of the punching punch in relation to the receiving device along the direction of movement of the punching punch can be carried out.

[0021] The plateau can also be a peak or an extreme point of the ramp.

[0022] The ramp element may have a plurality of ramps, and correspondingly, a plurality of support elements and a plurality of release areas may be present.

[0023] In an advantageous embodiment, the second thrust element is mechanically firmly connected to the ramp element. The receiving device can be supported on the ramp element in the direction toward the punching die. Similarly, the punching die can be supported on the support element in the direction toward the receiving device.

[0024] This means that in order to carry out a punching process, a force driving the punch is transferred from the receiving device to the ramp element, and from there to the support element, which transfers the force to the punch.

[0025] When the ramp element rests on the support element and the unlocking device is locked in this situation, a minimum distance between the punch and the die is realized in every relative position of the receiving device to the die, so that when the receiving device is translated and the punch is carried along in the movement of the receiving device, punching processes occur in the die.

[0026] However, if there is a discrepancy in the angular position of a positioning pin and the associated bushing, the positioning pin encounters a blocking area next to the bushing and is consequently displaced. The movement of the positioning pin is transmitted to the release device.

[0027] By transferring the movement of the positioning pin to the release device, a relative translation is realized between the ramp element and the support element, causing a plateau of the ramp element to move away from the support element and into the release area. Accordingly, there is no longer any support between the ramp element and the support element, and the release device is unlocked. This allows the punch to perform a relative translation with respect to the receiving device, allowing a greater distance between the punch and the die. Even with the receiving device continuously executing strokes, the punch is prevented from moving into the die as long as the positioning pin cannot move into the bushing.This ensures that if the angular positions of the positioning pin and bushing do not match, the punch does not move into the die, and consequently a collision of form elements of the punching punch with form elements of the die is excluded.

[0028] The relative translation of the punching punch can be effected in relation to the receiving device by means of at least one first spring unit, with which a first elastic restoring force can be applied to the punching punch at least when the unlocking device is in the unlocked situation.

[0029] If necessary, the first spring unit can exert a constantly acting spring force on the punching punch when the unlocking device is locked, so that when the unlocking device is unlocked, this spring force causes the relative translation of the punching punch in relation to the receiving device.

[0030] Furthermore, the unlocking device can comprise at least one second spring unit with which the second thrust element can be moved into a position which effects a locking of the unlocking device when the positioning bolt and bushing are arranged in angular positions which enable the positioning bolt to be inserted into the bushing.

[0031] If a force acts on the positioning bolt from a blocking area, and the positioning bolt is consequently displaced and the second pushing element is consequently also displaced in order to effect unlocking, and then a relative rotation between the punch and the die is carried out in such a way that the positioning bolt can move into the bushing, and as a result the positioning bolt is no longer subjected to a force from a blocking area, the second spring unit ensures, by means of a second elastic restoring force, that the second pushing element is moved back to its starting position and in this way, a locking of the unlocking device is realized, which fixes the relative position of the punch in relation to the receiving device along the movement axis of the punch, so that further punching processes can be carried out.

[0032] If, for example, the second thrust element is mechanically firmly coupled to the ramp element, the second spring unit ensures that when the positioning bolt can move into the bushing, the ramp element is moved again far enough so that a plateau of the ramp element comes to rest on the support element.

[0033] A further aspect of the present invention is a method for producing laminations of a laminated core of a power-generating component, such as a stator of an electrical rotary machine, in which a described device is provided and a sheet metal semi-finished product is provided, individual laminations are punched from the sheet metal semi-finished product by means of the device and between punching strokes between the punching punch and the die a relative rotational movement about the longitudinal axis of the punching punch is carried out in order to arrange differently aligned individual laminations in the die in a laminated core.

[0034] The sheets produced can be non-circular, but symmetrical around a certain angle or around at least one axis.

[0035] The individual sheets can each have n axes of symmetry, whereby in order to produce a sheet stack between the punching punch and the die around the longitudinal axis of the punching punch, at least 2n-1 relative rotational movements of the die in relation to the punching punch are realized in rotational positions in which punching operations are carried out.

[0036] Accordingly, it is intended to carry out at least 2n-1 rotational movements between the punch and the die around the longitudinal axis of the punch and to carry out the punching in the corresponding relative rotational positions.

[0037] The angle at which a respective relative rotational movement is carried out is accordingly 360° / 2n.

[0038] For example, if individual sheets are manufactured that have mounting holes regularly distributed around a circumference for the passage of a bolt to secure the individual sheets in a sheet stack, these individual sheets have two axes of symmetry. These two axes of symmetry allow the die to be positioned in four relative rotational positions relative to the punch by performing three relative rotational movements, and punching can be performed in these positions.

[0039] With the presented method and the associated device, a so-called mechanical control of the punch is possible, in which a punching process only takes place in permissible angular positions of the die in relation to the punch.

[0040] Another aspect of the present invention is an electric rotary machine comprising at least one power-generating component such as a stator or a rotor comprising laminations manufactured according to the described method.

[0041] The invention described above will be explained in detail below against the relevant technical background with reference to the accompanying drawings, which show preferred embodiments. The invention is in no way limited by the purely schematic drawings, and it should be noted that the embodiments shown in the drawings are not limited to the dimensions shown. It is shown in Fig. 1: the device for producing sheets of a laminated core in a sectional view showing a first state of the device, Fig. 2: the device for producing sheets of a sheet stack in a further detailed sectional view, Fig. 3: the device for producing sheets of a laminated core in a sectional view showing a second state of the device, and Fig. 4: the device for producing sheets of a sheet stack in a further detailed sectional view.

[0042] First, the basic structure of the device is explained using Fig. 1 explained.

[0043] The device comprises a punch 10, which is arranged on a receiving device 1. A movement of the receiving device 1 is transmitted to the punch 10, so that it can move along the direction of movement 11, which runs parallel to the longitudinal axis 12 of the punch 10, into a die 20, as shown in Fig. 1. There is a minimum distance of 80 between the punch 10 and the die 20.

[0044] This allows individual sheets to be punched out of a sheet metal semi-finished product not shown here.

[0045] Movable positioning pins 22 are connected to the receiving device 1. Bushings 23 are arranged in or next to the die, into which the positioning pins 22 can be inserted when the angular positions of the positioning pins 22 and the bushings 23 match, as shown in Fig. 1 shown.

[0046] The device further comprises an unlocking device 30, which serves to enable a relative translation 31 between the receiving device 1 and the punch 10 if there is no exact match between the positioning bolts 22 and the bushings 23.

[0047] Fig. 2 shows, in a further sectional view, a pressure unit 13 which comprises a plurality of pressure elements with which forces can be transferred from the receiving device 1 to the punching die 10 so that the latter can carry out the punching operations.

[0048] Furthermore, Fig. 2 a rotating device 25 and a drive wheel 26 connected to it. When the drive wheel 26 rotates, the rotating device 25 rotates and thus the die 20 rotates. In order to enable this rotary movement within a very short time and then also to stop it in a defined angular position, a drive motor is designed to implement a braking process. Furthermore, the device comprises a braking device 27 with brake shoes, which serve to brake the punched sheets in the rotating die and thus generate an axial braking force by means of frictional engagement between the sheets and the brake shoes. This braking force is required to mechanically arrange the individual sheets together in a compact sheet stack.

[0049] With these devices, it is possible to rotate the die 20 in relation to the punch 10 in a relative rotational movement 21 within a short time and thus to collect individual sheets in different orientations in a sheet stack within the die 20.

[0050] Due to the very high frequency of the strokes of the punch 10 as well as the speed of the relative rotational movement 21, it cannot be ruled out that the die 20 was not moved exactly into the intended angular position in relation to the punch 10, but that there is a slight deviation. This condition is in Fig. 3 shown.

[0051] Due to the deviations in the angular positions of the punch 10 and die 20, the positioning bolts 22 cannot reach the bushings 23, but instead hit blocking areas 24 next to the bushings 23.

[0052] This is in Fig. 3, it can be seen that the positioning pins 22 do not engage the bushings 23. In this situation, there is a greater distance 81 of the punch 10 in relation to the die 20, which is greater than the minimum distance 80, see Fig. 1.

[0053] The result is a displacement of the positioning pins 22 in the direction of the receiving device 1, wherein each positioning pin 22 applies a first thrust force 41 to a respective first thrust element 40, so that this first thrust element 40 is also displaced in the direction of the receiving device 1. Each first thrust element 40 comprises a first wedge element 42, which in the embodiment shown here forms an inclined plane that interacts with the inclined plane of a second thrust element 50, which has a second wedge element 52. As a result, a second thrust force is transmitted from the second thrust element substantially perpendicular to the direction of action of the first thrust force 41 to a ramp element 60 coupled to the second thrust element 50.

[0054] Fig. 1 shows the ramp element 60 shifted according to a first position 53 of the second

[0055] Shear element 50, and Fig. 3 shows the ramp element 60 displaced according to a second position 54 of the second thrust element 50.

[0056] The ramp element 60 has several plateaus 61, which are arranged in the Fig. 1, the support element 70 is supported. This fixes the distance between the receiving device 1 and the punch 10.

[0057] However, if it is in accordance with Fig. 3, the positioning bolts 22 cannot be moved into the bushings 23, the ramp elements 60 have shifted so that their plateaus 61 can no longer be supported on the support element 70, but have slipped off it and are now located in release areas 71 of the support element 70. As a result, as in Fig. 3, the punch 10 can approach the receiving device 1 in a relative translation 31. The consequence of this is that the punch 10 no longer moves into the die 20 and thus does not perform a punching operation. Furthermore, this also prevents the punch 10 from striking the die 20 in any way, which could lead to a collision between these two components due to the mismatch in the angular positions between the punch 10 and the die 20.

[0058] In Fig. 4, the first spring units 90 move the punch 10 in the direction of the receiving device 1 with first elastic restoring forces 91 in this case.

[0059] With a further or renewed relative rotation movement 21, a match of the angular positions between punch 10 and die 20 can be achieved again, so that, as in Fig. 1, the positioning bolts 22 retract into the bushings 23. In this situation, the Fig. 1, the second spring units 100 with respective second elastic restoring forces 101 ensure that the ramp elements 60 are again displaced to such an extent that their plateaus 61 are again supported on the support element 70, and thereby a rigid connection is again provided between the punch 10 and the receiving device 1.

[0060] The device and method proposed here for producing sheets of a laminated core of a power-generating component of an electric rotary machine provide solutions that enable a permanent punching process of sheets in a cost-effective and reliable manner. List of reference symbols 1 recording device 10 punches 11 Direction of movement 12 Longitudinal axis 13 printing unit 20 die 21 Relative rotational movement 22 positioning bolts 23 socket 24 Blocking area 25 Rotating device 26 Drive wheel 27 Braking device 30 Unlocking device 31 Relative translation 40 first thrust element 41 first thrust 42 first wedge element 50 second thrust element 51 second thrust 52 second wedge element 53 first position 54 second position 60 ramp element 61 Plateau 70 support element 71 Release area 80 minimum distance 81 greater distance 90 first spring unit 91 first elastic restoring force 100 second spring unit 101 second elastic restoring force

Claims

[1] A device for producing laminations of a laminated core of a power-generating component of an electrical rotary machine, comprising a receiving device (1) and a punch (10) mechanically connected thereto, and a die (20), wherein a relative rotational movement (21) about the longitudinal axis (12) of the punch (10) can be carried out between the punch (10) and the die (20), and at least one positioning bolt (22) on one of the two elements, punch (10) and die (20), and at least one bushing (23) on or in the other of the two elements, punch (10) and die (20), which are arranged and designed in such a way as to enable the positioning bolt (22) to be inserted into the bushing (23) when the angular relative position of the punch (10) to the die (20) is correct,and to prevent the positioning bolt (22) from being inserted into the bushing (23) if the relative angular position of the punch (10) to the die (20) is not correct, and thus to prevent the punch (10) from being inserted into the die (20). [2] Device for producing sheets of a laminated core according to claim 1, characterized by that on a radius on which the bushing (23) is arranged, the die (20) has at least one blocking area (24) with which a blocking of the retraction movement of the positioning bolt (22) into the die (20) can be realized. [3] Device for producing sheets of a laminated core according to claim 2, characterized byin that the positioning bolt (22) is mechanically connected to a first thrust element (40) which, when the retraction movement of the positioning bolt (22) is blocked and the positioning bolt (22) is displaced as a result, is also displaced and thereby actuates an unlocking device (30) in such a way that unlocks a fixing of the punching punch (10) to the receiving device (1) and in such a way that a relative translation (31) is carried out between the receiving device (1) and the punching punch (10), so that when the relative translation (31) is carried out, a retraction of the punching punch (10) into the die (20) can be prevented when the receiving device (1) moves towards the die (20). [4] Device for producing sheets of a laminated core according to claim 3, characterized byin that the unlocking device (30) comprises at least one wedge element (42, 52) which, under the action of a first thrust force (41) applied by the first thrust element (40), displaces a second thrust element (50) using the principle of the inclined plane, wherein the second thrust element (50) is designed to lock the unlocking device (30) in a first position (53) and to release the unlocking device (30) in a second position (54). [5] Device for producing sheets of a laminated core according to claim 4, characterized by that the unlocking device (30) comprises a first wedge element (42) as a component of the first pushing element (40), and a second wedge element (52) as a component of the second pushing element (50), wherein inclined planes of the two wedge elements (42, 52) abut one another. [6] Device for producing sheets of a laminated core according to one of claims 4 and 5, characterized bythat the unlocking device (30) comprises a ramp element (60), a support element (70) and a release area (71), wherein the receiving device (1) is supported on one of the two elements, ramp element (60) and support element (70), and the punching punch (10) is supported on the other of the two elements, ramp element (60) and support element (70), and wherein the second pushing element (50) is mechanically connected to one of the two elements, ramp element (60) and support element (70), which is also displaceable driven by a second pushing force (51) caused by the second pushing element (50), wherein in a locked situation of the unlocking device (30), a plateau (61) of the ramp element (60) rests on the support element (70) and thereby determines the relative position of the punching punch (10) in relation to the receiving device (1) along the direction of movement (11) of the punching die (10) is fixed,and in an unlocked situation of the unlocking device (30), the ramp element (60) is located in the release area (71), and thereby a relative translation (31) of the punch (10) with respect to the receiving device (1) along the direction of movement (11) of the punch (10) can be carried out. [7] Device for producing sheets of a laminated core according to claim 6, characterized by that the relative translation (31) of the punching punch (10) in relation to the receiving device (1) can be effected by means of at least one first spring unit (90), with which a first elastic restoring force (91) can be applied to the punching punch (10) at least when the unlocking device (30) is in the unlocked situation. [8] Method for producing sheets of a laminated core of a power-generating component of an electrical rotary machine, in which a device according to one of claims 1 to 7 is provided and a semi-finished sheet metal product is provided, individual sheets are punched from the semi-finished sheet metal product by means of the device and between punching strokes between the punching punch (10) and the die (20) a relative rotational movement (21) about the longitudinal axis (12) of the punching punch (10) is carried out in order to arrange differently aligned individual sheets in the die (20) in a laminated core. [9] Method for producing sheets of a laminated core according to claim 8, characterized bythat the individual sheets each have n axes of symmetry, and in order to produce a sheet stack between the punching punch (10) and the die (20) about the longitudinal axis (12) of the punching punch (10), at least 2n-1 relative rotational movements (21) of the die (20) in relation to the punching punch (10) are realized in rotational positions in which punching operations are carried out. [10] An electric rotary machine comprising at least one power generating component comprising laminations produced according to the method of any one of claims 8 and 9.

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