Manufacturing method of processed products

Abstract

This disclosure provides a method for manufacturing a processed product that can remove defects present in a strip-shaped member and eliminate the impact of those defects on the product. [Solution] The method includes detecting a defect M contained in a strip-shaped member MS that is sent in a predetermined one direction before it reaches the press working device, and when a defect is detected by the detection unit SE2, a predetermined removal area of ​​the strip-shaped member that includes at least a part of the defect and includes an outer shape punching area that is to be punched out by an outer shape punching unit provided by the press working device, is cut by laser light irradiated from the irradiation unit 122 of the laser device, thereby removing the removal area from the strip-shaped member and forming a through hole for blank punching in the removal area of ​​the strip-shaped member, and punching out the outer shape punching area of ​​the strip-shaped member where the removal area has not been formed by the outer shape punching unit to form a processed product. The size of the removal area is larger than the size of the outer shape punching area.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a processed product.

Background Art

[0002] Patent Document 1 discloses a method for manufacturing a laminated iron core, comprising a step of sequentially punching a processed member, in which the terminal end of a preceding belt-shaped processed member and the start end of a subsequent belt-shaped processed member are welded by a cutting and welding device, with a press device in a staggered pattern of two or more rows in the width direction of the processed member to form iron core plates. The cutting and welding device is configured to cut and weld the terminal end of the preceding processed member and the start end of the subsequent processed member at a position that is a diagonal straight line relative to the width direction perpendicular to the feeding direction of the processed members and that avoids the rotor iron core plates among the iron core plates.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, according to the method of Patent Document 1, it is not possible to remove defective portions (for example, scratches extending in a predetermined direction, spot-like scratches, etc.) existing in the middle of the processed member from the processed member. As a result, iron core pieces containing defective portions may be mixed into the product (laminated iron core), which may affect the characteristics of the product. This applies not only to welded portions and defective portions, but also to cases where a belt-shaped processed member contains a flawed portion that may affect the product.

[0005] Accordingly, the present disclosure describes a method for manufacturing a processed product that can remove flawed portions present in a belt-shaped member and eliminate the influence of the flawed portions on the product.

Means for Solving the Problems

[0006] An example of a method for manufacturing a processed product includes: a first step of detecting a defect in a strip-shaped member that is sent out in a predetermined direction by a feeding device before the defect reaches the press working device; a second step of removing a predetermined removal area from the strip-shaped member, which includes at least a part of the defect and is subject to punching out by the outer shape punching section of the press working device, by cutting the removal area with laser light emitted from the irradiation section of a laser device located upstream of the press working device in the feeding direction of the strip-shaped member, thereby forming a through hole for blank punching in the removal area of ​​the strip-shaped member; and a third step of punching out the outer shape punching area of ​​the strip-shaped member where the removal area has not been formed by the outer shape punching section to form a processed product. The size of the removal area is set to be larger than the size of the outer shape punching area. [Effects of the Invention]

[0007] According to the manufacturing method of the processed product described herein, it is possible to remove defects present in the strip-shaped member and eliminate the impact of defects on the product. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view showing an example of a laminated iron core. [Figure 2] Figure 2 is a cross-sectional view taken along line II-II in Figure 1. [Figure 3] Figure 3 is a schematic side view showing an example of a laminated iron core manufacturing apparatus. [Figure 4] Figure 4 is a schematic side view showing an example of a laser device and a transmission device. [Figure 5] Figure 5 is a schematic side view showing an example of a press working apparatus. [Figure 6] Figure 6 is a schematic top view showing an example of a die component. [Figure 7] Figure 7 shows an example of a processing layout for punched-out parts. [Figure 8]Figure 8 shows an example of a processing layout when a through-hole is formed in a strip of metal plate by a laser device and the through-hole reaches the first processing unit. [Figure 9] Figure 9 shows an example of a processing layout when a through-hole is formed in a strip of metal plate by a laser device and the through-hole reaches a second processing unit. [Figure 10] Figure 10 shows an example of a processing layout when a through-hole is formed in a strip of metal plate by a laser device and the through-hole reaches a third processing unit. [Figure 11] Figure 11 shows an example of a processing layout when a through-hole is formed in a strip of metal plate by a laser device and the through-hole reaches a fourth processing unit. [Figure 12] Figure 12 shows an example of a processing layout when a through-hole is formed in a strip of metal plate by a laser device and the through-hole reaches a fifth processing unit. [Figure 13] Figure 13 is a diagram illustrating a method for correcting the displacement amount δ1, and is a schematic top view showing the laser device and the press working device. [Figure 14] Figure 14 is a diagram illustrating a method for correcting the displacement amount δ2, and is a schematic top view showing the laser device and the press working device. [Figure 15] Figure 15 is a schematic side view showing another example of a laser device along with a laser delivery device. [Figure 16] Figure 16 is a schematic side view showing another example of a press working apparatus. [Figure 17] Figure 17 is a diagram illustrating how the position of the lower die in the feeding direction and the position of the lower die in a direction intersecting the feeding direction are detected, and is a schematic top view showing the laser device and the press working device. [Figure 18] Figure 18 shows a strip of metal plate with detection through-holes provided, and is a schematic top view of the laser device and press working device. [Figure 19]FIG. 19(a) is a side view schematically showing a state in which a detection pin is inserted through a detection through-hole, and FIG. 19(b) is a side view schematically showing a state in which a detection pin is not inserted through the detection through-hole. [Description of Embodiments]

[0009] In the following description, the same reference numerals are used for the same elements or elements having the same functions, and duplicate descriptions are omitted. In the present specification, references to up, down, right, and left in the drawings are based on the orientation of the reference numerals in the drawings.

[0010] [Configuration of Laminated Core] First, the configuration of the laminated core 1 will be described with reference to FIG. 1 and FIG. 2. In FIG. 1 and FIG. 2, a stator laminated core is illustrated as an example of the laminated core 1. The stator laminated core is a part of a stator. The stator is configured by attaching windings to the stator laminated core. A motor is configured by combining the stator with a rotor.

[0011] The laminated core 1 has a cylindrical shape as a whole. A central hole 1a penetrating the laminated core 1 so as to extend along the central axis Ax is provided in the central portion of the laminated core 1. The central hole 1a extends in the height direction (lamination direction) of the laminated core 1. A rotor can be disposed inside the central hole 1a.

[0012] The laminated core 1 is a laminated body 2 in which a plurality of punched members W (processed products) are stacked. The punched member W is a plate-shaped body obtained by punching a strip-shaped metal plate MS (strip-shaped member), which will be described later, into a predetermined shape. The laminated core 1 may be configured by a plurality of punched members W that are rotationally laminated. "Rotational lamination" refers to laminating a plurality of punched members W while relatively shifting the angle between the punched members W. Rotational lamination is mainly performed for the purpose of offsetting the plate thickness deviation of the punched members W to improve the flatness, parallelism, and squareness of the laminated core 1. The angle of rotational lamination may be set to an arbitrary magnitude.

[0013] The laminated core 1 includes a yoke portion 3, a plurality of teeth portions 4, and a plurality of joint portions 5. The yoke portion 3 is annular in shape and extends to surround the central axis Ax. As illustrated in Figure 1, the yoke portion 3 may also be circular in shape. The plurality of teeth portions 4 extend along the radial direction of the yoke portion 3 from its inner edge toward the central axis Ax. That is, the plurality of teeth portions 4 protrude from the inner edge of the yoke portion 3 toward the central axis Ax. The plurality of teeth portions 4 may be arranged at approximately equal intervals in the circumferential direction of the yoke portion 3. Between adjacent teeth portions 4, slots 6 are defined, which are spaces for arranging windings (not shown). The plurality of teeth portions 4 may also protrude radially outward from the outer edge of the yoke portion 3.

[0014] The joint 5 may be provided on the yoke portion 3, on each tooth portion 4, or on both the yoke portion 3 and each tooth portion 4. In the example shown in Figures 1 and 2, the joint 5 is provided on each tooth portion 4. The joint 5 may also be a crimped portion, as illustrated in Figures 1 and 2. In this case, the joint 5 includes a crimp 5a formed in the punched member W that makes up all but the bottom layer of the laminate 2, and a through hole 5b formed in the punched member W that makes up the bottom layer of the laminate 2, as illustrated in Figure 2.

[0015] Each crimp 5a consists of a recess formed on one main surface (upper surface in Figure 2) of the punched member W and a protrusion formed on the other main surface (lower surface in Figure 2) of the punched member W. The recess of the crimp 5a of one punched member W is joined to the protrusion of the crimp 5a of another punched member W adjacent to the one main surface of that punched member W. The protrusion of the crimp 5a of one punched member W is joined to the recess of the crimp 5a of yet another punched member W adjacent to the other main surface of that punched member W. The protrusion of the crimp 5a of a punched member W adjacent to the bottom layer of the laminate 2 is joined to the through hole 5b. The through hole 5b has the function of preventing a subsequently formed punched member W from being fastened by the crimp 5a to an already manufactured laminate 2 when the laminate 2 is manufactured continuously.

[0016] The joint 5 may be a bonding agent (for example, an adhesive, a resin material, etc.) that joins adjacent punched members W in the stacking direction. The joint 5 may also be a welded joint that joins adjacent punched members W in the stacking direction.

[0017] [Laminated Iron Core Manufacturing Equipment] The manufacturing apparatus 100 for laminated iron cores will be described with reference to Figures 3 and 4. The manufacturing apparatus 100 is configured to manufacture laminated iron cores 1 from strip metal plates MS. As illustrated in Figure 3, the manufacturing apparatus 100 includes an uncoiler 110, a laser device 120, a feeding device 130, a press working device 200, and a controller Ctr (control unit).

[0018] The uncoiler 110 is configured to rotatably hold the coil material 111. The coil material 111 is made of a strip of metal sheet MS wound in a coil (spiral) shape. The strip of metal sheet MS may have a defect M.

[0019] The defective part M may be, for example, a weld formed by welding the rear end of one coil material 111 to the front end of another coil material 111. In this case, the weld may extend from one side edge of the coil material 111 to the other side edge. The weld may extend along the width direction of the coil material 111. The weld extending along the width direction of the coil material 111 may include extending substantially perpendicular to the side edge of the coil material 111 when viewed from the main surface side of the strip metal plate MS. The weld extending along the width direction of the coil material 111 may also include extending obliquely so as to intersect the perpendicular to the side edge of the coil material 111 when viewed from the main surface side of the strip metal plate MS. The weld may extend in a straight line, in a curved line, or while bending.

[0020] The defective part M may be, for example, a faulty part (e.g., a scratch extending in a predetermined direction, a spot-shaped scratch, etc.). For example, an indicator may be attached to the strip-shaped metal plate MS corresponding to the defective part M in order to indicate the location of the defective part M on the strip-shaped metal plate MS. The indicator may be attached to the strip-shaped metal plate MS in the vicinity of the defective part M. The indicator may be, for example, a letter, a figure, a symbol (including a barcode, a two-dimensional code, etc.), a mark, etc. The indicator may be, for example, handwritten by a person using a pen, engraved by laser processing, etc., or a small piece with an adhesive layer (e.g., a sticker, a sticky note, etc.) attached.

[0021] The laser device 120 is configured to laser process a strip-shaped metal plate MS to remove a portion of the strip-shaped metal plate MS. Details of the laser device 120 will be described later.

[0022] The feeding device 130 includes a pair of rollers 131 and 132 and a guide section 133, as illustrated in Figures 3 and 4. The pair of rollers 131 and 132 operate based on instruction signals from the controller Ctr and are configured to rotate and stop while gripping the strip metal plate MS from above and below. As a result, the pair of rollers 131 and 132 intermittently feed the strip metal plate MS along its longitudinal direction in a predetermined one direction (the direction from the rollers 131 and 132 toward the press working device 200, which is the direction of arrow Ar1 in Figures 3 and 4). In this document, the one direction in which the strip metal plate MS is fed by the rollers 131 and 132 may be referred to as the "feeding direction".

[0023] The guide section 133 is positioned between the laser device 120 and the rollers 131 and 132, and is configured to guide the strip-shaped metal plate MS in the delivery direction. The guide section 133 may include a plurality of guide paths 133a and a hinge section 133b, as illustrated in Figure 4. The plurality of guide paths 133a have a rectangular tubular shape and are configured so that the strip-shaped metal plate MS can pass through them. The width and height of the internal space of the guide paths 133a may be set to be, for example, about 1 mm to 5 mm larger than the width and thickness of the strip-shaped metal plate MS. The plurality of guide paths 133a are arranged in series in the delivery direction.

[0024] The hinge portion 133b includes a plurality of rotatable rotating shafts and link members connecting the rotating shafts. The hinge portion 133b is configured to connect adjacent guide paths 133a in the delivery direction. By connecting the guide paths 133a with the hinge portion 133b, the plurality of guide paths 133a can move closer to and further apart from each other, and can be inclined with respect to the delivery direction. Therefore, even when the strip metal plate MS moves up and down due to vibrations generated in conjunction with the operation of the press working machine 200, the guide portion 133 can stably guide the strip metal plate MS.

[0025] The press working apparatus 200 is configured to operate based on instruction signals from the controller Ctr. As illustrated in Figure 3, the press working apparatus 200 is configured to sequentially punch out a strip of metal sheet MS fed by rollers 131 and 132 using multiple punches to form multiple punched members W. The press working apparatus 200 may also be configured to sequentially stack the multiple punched members W obtained by punching to form a laminated iron core 1. Details of the press working apparatus 200 will be described later.

[0026] As illustrated in Figure 3, the controller Ctr is configured to generate instruction signals for operating the laser device 120, the feeder 130, and the press working device 200 based on a program recorded on a recording medium (not shown) or operation input from an operator. The controller Ctr is configured to transmit these instruction signals to the laser device 120, the feeder 130, and the press working device 200, respectively.

[0027] [Details of the press working equipment] Next, the details of the press working apparatus 200 will be described with reference to Figures 5 to 7. As illustrated in Figure 5, the press working apparatus 200 includes a lower part 210, an upper part 220, a press machine 230, and a detection unit SE1 (and another detection unit).

[0028] (A) Configuration of the lower part 210 The lower section 210 includes a bolster 211, a die holder 212 (mold), a die member 213 (mold), a plurality of guide posts 214, and a transport mechanism 215. In this document, at least one of the die holder 212 and the die member 213 may be referred to as the "lower mold 210A".

[0029] The bolster 211 is grounded to the floor FL via a vibration isolation device 216. Therefore, vibrations associated with the operation of the press working machine 200 are reduced by the vibration isolation device 216. Alternatively, the bolster 211 may be directly fixed to the floor FL without the vibration isolation device 216. The press working machine 200 may also have a press bed as its base. In that case, the bolster 211 may be mounted on the press bed, and the press bed may be installed on the floor FL via the vibration isolation device 216.

[0030] The die holder 212 is mounted on the bolster 211. The die holder 212 has a plurality of discharge holes C1 to C5. The discharge holes C1 to C5 may extend vertically inside the die holder 212. Material punched out from the strip metal sheet MS (e.g., punched member W, waste material, etc.) is discharged to the outside of the press working apparatus 200 through the discharge holes C1 to C5. The discharge holes C1 to C5 may extend to the bolster 211. In that case, the bolster 211 may also have holes communicating with the discharge holes C1 to C5, and the material punched out from the strip metal sheet MS may be discharged to the outside through these holes.

[0031] A squeeze ring Q is housed within the discharge hole C5. The squeeze ring Q is cylindrical and located below the die D5, which will be described later. The squeeze ring Q may be in contact with the die D5 or may be separated from it. A through hole extending vertically through the center of the squeeze ring Q communicates with the die hole D5a of the die D5, forming a single through hole as a whole.

[0032] The die member 213 is installed in the die holder 212. The die member 213 includes a die plate 213a and a plurality of dies D1 to D5, as illustrated in Figures 5 and 6. The die plate 213a is configured to hold the plurality of dies D1 to D5. The die plate 213a is provided with a plurality of holding holes E1 to E5 and a plurality of insertion holes F1 to F5.

[0033] The multiple retaining holes E1 to E5 are arranged in this order along the delivery direction, as illustrated in Figures 5 and 6. Retaining holes E1 are provided near both side edges of the die plate 213a, as illustrated in Figure 6, and hold the die D1. Retaining holes E2 to E5 are provided in the central part of the die plate 213a, and hold the dies D2 to D5.

[0034] Multiple through holes F1 to F5 are arranged at approximately equal intervals in this order along the delivery direction, as illustrated in Figures 5 and 6. Through holes F1 are provided near both side edges of the die plate 213a, as illustrated in Figure 6, and are located upstream of the retaining hole E2. Through holes F2 are provided near both side edges of the die plate 213a, and are located between retaining holes E2 and E3. Through holes F3 are provided near both side edges of the die plate 213a, and are located between retaining holes E3 and E4. Through holes F4 are provided near both side edges of the die plate 213a, and are located between retaining holes E4 and E5. Through holes F5 are provided near both side edges of the die plate 213a, and are located downstream of the retaining hole E5.

[0035] Multiple dies D1 to D5 are arranged in this order along the delivery direction, as illustrated in Figures 5 and 6. Each of the multiple dies D1 to D5 is provided with die holes D1a to D5a that penetrate in the vertical direction.

[0036] Die D1, together with punch P1 (described later), constitutes a first processing unit for punching out a strip of metal sheet MS. By inserting and removing punch P1 into die hole D1a of die D1, the strip of metal sheet MS is punched out in a shape that follows the contour of die hole D1a of die D1. Die hole D1a may have a shape corresponding to the outer shape of positioning pins B1 to B5 (described later), and may, for example, be circular. As a result, as illustrated in Figure 7, positioning holes H1 that penetrate the strip of metal sheet MS are formed near both side edges of the strip of metal sheet MS. The metal pieces punched out from the strip of metal sheet MS by the first punching unit are discharged to the outside of the press working apparatus 200 through die hole D1a and discharge hole C1.

[0037] In Figure 7, the areas filled in black indicate that the strip metal plate MS is punched or processed by punches P1 to P5, which will be described later, in that area. In Figure 7, the areas where black and white sectors are arranged alternately in the circumferential direction indicate that the positioning pins B1 to B5, which will be described later, are inserted into the positioning holes H1 in that area.

[0038] As illustrated in Figure 6, when viewed from above, the center of the die hole D1a and the center of the insertion hole F1 in the feeding direction are separated by a predetermined distance d. Among the multiple insertion holes F1 to F5, the centers of adjacent insertion holes in the feeding direction are also separated by a distance d. This distance d is the feed pitch of the strip metal plate MS that is intermittently fed by rollers 131 and 132.

[0039] As illustrated in Figures 5 and 6, die D2, together with punch P2 (described later), constitutes a second processing unit for punching out a strip of metal sheet MS. By inserting and removing punch P2 into die hole D2a of die D2, the strip of metal sheet MS is punched out in a shape that follows the contour of die hole D2a of die D2. The die hole D2a may also have a shape that corresponds to the outer shape of the slot 6 of the laminated iron core 1. As a result, as illustrated in Figure 7, multiple through holes H2 penetrating the strip of metal sheet MS are formed in the central part of the strip of metal sheet MS. The multiple through holes H2 are positioned to be aligned along a circular shape. Each through hole H2 has a shape that corresponds to the slot 6 of the laminated iron core 1. The metal pieces punched out from the strip of metal sheet MS by the second punching unit are discharged to the outside of the press working apparatus 200 through die hole D2a and discharge hole C2.

[0040] As illustrated in Figures 5 and 6, die D3, together with punch P3 (described later), constitutes a third processing unit (switching processing unit) for selectively punching or pressing (e.g., cutting and bending, half-punching, etc.) a strip-shaped metal sheet MS. By inserting and removing punch P3 into die hole D3a of die D3, the strip-shaped metal sheet MS is punched or pressed in a shape that follows the contour of die hole D3a of die D3. The die hole D3a may have a shape corresponding to the outer shape of the crimp 5a and through hole 5b, and may, for example, be circular. As a result, as illustrated in Figure 7, a plurality of processing parts H3 are formed in the central part of the strip-shaped metal sheet MS. Each processing part H3 is located between adjacent through holes H2 among a plurality of through holes H2. The processing part H3 is a through hole that penetrates the strip-shaped metal sheet MS and corresponds to the through hole 5b of the joint 5, or an uneven part formed on the strip-shaped metal sheet MS and corresponds to the crimp 5a of the joint 5. When the processing section H3 is a through hole, the metal piece punched out from the strip metal sheet MS by the third punching unit is discharged to the outside of the press working device 200 through the die hole D3a and the discharge hole C3.

[0041] As illustrated in Figures 5 and 6, die D4, together with punch P4 (described later), constitutes a fourth processing unit for punching out a strip of metal sheet MS. By inserting and removing punch P4 into die hole D4a of die D4, the strip of metal sheet MS is punched out in a shape that follows the contour of die hole D4a of die D4. The die hole D4a may have a shape corresponding to the outer shape of the central hole 1a of the laminated iron core 1, and may, for example, be circular. As a result, as illustrated in Figure 7, a through hole H4 that penetrates the strip of metal sheet MS is formed in the center of the strip of metal sheet MS. The through hole H4 overlaps with the inner circumferential ends of the multiple through holes H2. The through hole H4 has a shape corresponding to the central hole 1a of the laminated iron core 1. The metal pieces punched out from the strip of metal sheet MS by the fourth punching unit are discharged to the outside of the press working apparatus 200 through die hole D4a and discharge hole C4.

[0042] As illustrated in Figures 5 and 6, die D5, together with punch P5 and squeeze ring Q (described later), constitutes a fifth processing unit (outer shape punching section) for punching out a strip-shaped metal sheet MS. By inserting and removing punch P5 into die hole D5a of die D5, the strip-shaped metal sheet MS is punched out in a shape that follows the contour of die hole D5a of die D5. The die hole D5a may have a shape corresponding to the outer shape of the laminated iron core 1 (punched member W), and may, for example, be circular. As a result, as illustrated in Figure 7, a through hole H5 that penetrates the strip-shaped metal sheet MS is formed in the center of the strip-shaped metal sheet MS. The through hole H5 has a shape corresponding to the outer shape of the laminated iron core 1 (punched member W). In this document, the region of the strip-shaped metal sheet MS in which the through hole H5 is formed, that is, the region targeted for punching by the fifth processing unit (die D5 and punch P5), is referred to as the outer shape punching region R2.

[0043] If the third processing unit has a recessed area R2 corresponding to the crimp 5a, the punched members W punched out from the strip metal sheet MS by the fifth punching unit are stacked with the previously punched punched members W within the die hole D5a and squeeze ring Q, fastened together by the crimp 5a. If the third processing unit has a through hole corresponding to the through hole 5b formed in the outer shape punching area R2, the punched members W punched out from the strip metal sheet MS by the fifth punching unit are not fastened to the crimp 5a of the previously punched punched members W, but are placed on top of the previously punched punched members W within the die hole D5a and squeeze ring Q. When a predetermined number of punched members W are stacked within the die hole D5a and squeeze ring Q, the resulting stacked iron core 1 is placed on the transport mechanism 215 through the discharge hole C5 and transported out of the press working device 200 by the transport mechanism 215.

[0044] The through-hole shape of the squeeze ring Q may be substantially the same as the die hole D5a of the die D5 when viewed from above. The through-hole shape of the squeeze ring Q may be set to be slightly smaller than the die hole D5a of the die D5 when viewed from above. In this case, when the punched member W punched out by the die D5 passes through the die D5 and reaches the squeeze ring Q, a lateral pressure acting on the punched member W from the outer circumference toward the inside acts on the punched member W. As a result, the punched member W is held by the squeeze ring Q and is less likely to fall downward, so that the joining by crimping 5a between it and the subsequent punched member W can be performed more reliably.

[0045] As illustrated in Figure 5, the multiple guide posts 214 extend linearly upward from the die holder 212. The multiple guide posts 214, together with the guide bush 221a (described later), are configured to guide the upper part 220 in the vertical direction. The multiple guide posts 214 may also be attached to the punch holder 221 (described later) so as to extend downward from the upper part 220.

[0046] The conveying mechanism 215 operates based on instructions from the controller Ctr and is configured to send the laminated iron core 1 discharged from the squeeze ring Q to a subsequent device (e.g., a welding device). The conveying mechanism 215 may be, for example, a belt conveyor.

[0047] (B) Configuration of the upper 220 The upper part 220 includes a punch holder 221 (upper die, mold), a stripper 222, a plurality of punches P1 to P5, a plurality of positioning pins B1 to B5, and a switching device 223 (switching processing section).

[0048] The punch holder 221 is positioned above the die holder 212 and the die member 213, facing them. The punch holder 221 is configured to hold a plurality of punches P1 to P5 and a plurality of positioning pins B1 to B5. The plurality of punches P1 to P5 and the plurality of positioning pins B1 to B5 held by the punch holder 221 protrude downward from the lower surface of the punch holder 221.

[0049] The punch holder 221 is provided with a plurality of cylindrical guide bushes 221a. Each of the guide bushes 221a is positioned to correspond to a plurality of guide posts 214 when viewed from above. Each guide post 214 is slidable within the corresponding guide bush 221a. If the guide posts 214 are attached to the punch holder 221, the guide bushes 221a may be provided on the die holder 212.

[0050] The punch holder 221 is provided with multiple through holes 221b. A stepped shape is formed on the inner circumferential surface of the through holes 221b. Therefore, the diameter of the upper part of the through hole 221b is set to be smaller than the diameter of the lower part of the through hole 221b.

[0051] The stripper 222 is configured to separate the strip metal sheet MS from the punches P1 to P5 when the strip metal sheet MS is pressed into the punches P1 to P5. The stripper 222 is positioned between the die member 213 and the punch holder 221.

[0052] The stripper 222 is connected to the punch holder 221 via a connecting member 224. The connecting member 224 includes an elongated body and a head provided at the upper end of the body. The body of the connecting member 224 is inserted into the lower part of the through hole 221b and is movable up and down within the through hole 221b. The lower end of the body of the connecting member 224 is fixed to the stripper 222. The head of the connecting member 224 is located above the through hole 221b.

[0053] The head of the connecting member 224 is larger than the main body of the connecting member 224 and the lower part of the through hole 221b when viewed from above. Therefore, it can move up and down within the upper part of the through hole 221b, but it cannot move within the lower part of the through hole 221b. In other words, the step formed between the upper and lower parts of the through hole 221b acts as a stopper, preventing the head of the connecting member 224 from moving below the step.

[0054] Because the connecting member 224 and the through hole 221b are in the relationship described above, the stripper 222 is suspended and held on the punch holder 221 via the connecting member 224 so that it can move up and down relative to the punch holder 221. A biasing member 225 (for example, a compression coil spring) may be attached around the main body of the connecting member 224 so as to be positioned between the punch holder 221 and the stripper 222.

[0055] The stripper 222 has through holes at positions corresponding to punches P1 to P5 and multiple positioning pins B1 to B5. Each through hole extends vertically and, when viewed from above, overlaps with the die holes D1a to D5a and insertion holes F1 to F of the corresponding dies D1 to D5. The lower parts of the corresponding punches P1 to P5 and the lower parts of the positioning pins B1 to B5 are inserted into each through hole. The punches P1 to P5 and the positioning pins B1 to B5 are slidable within their respective through holes.

[0056] The punches P1 to P5 are arranged in this order in the feeding direction. The lower end of punch P1 has a shape corresponding to the die hole D1a of die D1. The number of punches P1 may be the same as the number of die holes D1a of die D1. The first punching unit, consisting of punches P1 and die D1, forms a plurality of positioning holes H1 in a strip of metal sheet MS. The first punching unit may punch out the strip of metal sheet MS in the same process to form a plurality of positioning holes H1 in the strip of metal sheet MS almost simultaneously.

[0057] The lower end of the punch P2 has a shape corresponding to the die hole D2a of the die D2. The number of punches P2 may be the same as the number of die holes D2a of the die D2. The second punching unit, composed of punches P2 and die D2, forms a plurality of through holes H2 in the strip metal sheet MS. The second punching unit may punch the strip metal sheet MS in the same process to form a plurality of through holes H2 in the strip metal sheet MS substantially simultaneously.

[0058] The lower end of the punch P3 has a shape corresponding to the die hole D3a of the die D3. The number of punches P3 may be the same as the number of die holes D3a of the die D3. The third punching unit, composed of the punch P3 and the die D3, selectively forms one of a plurality of crimps 5a and one of a plurality of through holes 5b on the strip metal sheet MS. The third punching unit may process the strip metal sheet MS in the same process to selectively form one of the crimps 5a and one of the through holes 5b on the strip metal sheet MS almost simultaneously. Switching between forming one of the crimps 5a and one of the through holes 5b on the strip metal sheet MS is performed by a switching device 223, which will be described later.

[0059] The lower end of the punch P4 has a shape corresponding to the die hole D4a of the die D4. The fourth punching unit, consisting of the punch P4 and the die D4, punches out a strip of metal sheet MS to form a through hole H4 in the strip of metal sheet MS.

[0060] The lower end of the punch P5 has a shape corresponding to the die hole D5a of the die D5. The fifth punching unit, consisting of the punch P5 and die D5, punches out a strip of metal MS to form a punched member W (also called "outer shape punching").

[0061] Positioning pins B1 to B5 are arranged in this order in the feeding direction. Positioning pin B1 is located between punches P1 and P2 so as to overlap with the insertion hole F1 when viewed from above. Positioning pin B2 is located between punches P2 and P3 so as to overlap with the insertion hole F2 when viewed from above. Positioning pin B3 is located between punches P3 and P4 so as to overlap with the insertion hole F3 when viewed from above. Positioning pin B4 is located between punches P4 and P5 so as to overlap with the insertion hole F4 when viewed from above. Positioning pin B5 is located downstream of punch P5 so as to overlap with the insertion hole F5 when viewed from above.

[0062] The switching device 223 is positioned above the punch P3 in a housing space 221c formed within the punch holder 221. If the press working apparatus 200 includes multiple punches P3, the same number of switching devices 223 as the number of punches P3 may be positioned above each individual punch P3 to correspond to it.

[0063] The switching device 223 is, for example, a cam mechanism and includes a cam member 223a and an actuator 223b. The cam member 223a is configured to slide horizontally within the housing space 221c. The lower surface of the cam member 223a is provided with a recess 223c that is recessed upward. The recess 223c is configured to accommodate the head of the punch P3.

[0064] The actuator 223b is configured to drive the cam member 223a horizontally based on an instruction signal from the controller Ctr. The actuator 223b may be configured to move the cam member 223a between, for example, a first position in which the head of the punch P3 is located outside the recess 223c and in contact with the lower surface of the cam member 223a, and a second position in which the head of the punch P3 is housed inside the recess 223c. The actuator 223b may be located outside the upper part 220 rather than inside the housing space 221c.

[0065] When the cam member 223a is in the first position, the tip of the punch P3 protrudes downward compared to when it is in the second position. Therefore, when the cam member 223a is in the first position, the strip metal plate MS is punched out by the punch P3 and die D3, and a through hole corresponding to the through hole 5b is formed in the strip metal plate MS. On the other hand, when the cam member 223a is in the second position, the strip metal plate MS is half-punched by the punch P3 and die D3, and a recessed portion corresponding to the crimp 5a is formed in the strip metal plate MS.

[0066] (C) Configuration of press machine 230 The press machine 230 is connected to the punch holder 221 and operates based on instructions from the controller Ctr. When the press machine 230 is operating, the upper part 220 moves up and down as a whole.

[0067] (D) Configuration of the detection unit SE1 The detection unit SE1 is configured to detect the position of the through-hole G (described later) formed in the strip-shaped metal plate MS in the delivery direction. The detection unit SE1 is located upstream of the lower die 210A in the delivery direction. That is, the detection unit SE1 is configured to detect the position of the through-hole G in the delivery direction before it reaches the lower die 210A. The detection unit SE1 may be provided on the upstream end face of the lower die 210A in the delivery direction. In the example of Figure 5, the detection unit SE1 is provided on the upstream end face 212a of the die holder 212 in the delivery direction. The detection unit SE1 is configured to transmit the detected position of the through-hole G in the delivery direction to the controller Ctr. The detection unit SE1 is not particularly limited as long as it can detect the position of the through-hole G in the delivery direction, but it may be a non-contact sensor such as a laser distance sensor, photoelectric sensor, or image sensor.

[0068] [Details of the laser device] As illustrated in Figure 4, the laser device 120 includes a base 121, an irradiation unit 122, a pressing member 123, a cutting blade 124, a suction unit 125, a detection unit SE2, and a detection unit SE3 (and another detection unit).

[0069] The base 121 is fixed to the floor FL. The base 121 is provided with a discharge hole 121a that opens upward. The strip-shaped metal plate MS is transported by the guide portion 133 so as to move above the upper surface of the base 121.

[0070] The irradiation unit 122 is positioned above the discharge hole 121a of the base 121. The irradiation unit 122 is configured to irradiate the strip-shaped metal plate MS located below it with laser light based on an instruction signal from the controller Ctr. Specifically, the irradiation unit 122 is configured to irradiate the strip-shaped metal plate MS with laser light along the contour of a predetermined removal area R1 (see Figures 8 to 12) within the strip-shaped metal plate MS, thereby cutting the strip-shaped metal plate MS along the contour and forming through holes G (through holes for dummy firing) (see Figures 5 and 8 to 12) in the strip-shaped metal plate MS with a shape corresponding to the removal area R1.

[0071] The size of the removal area R1 is set to be larger than the size of the outer shape cutting area R2, which will be described later. The shape of the removal area R1 is not particularly restricted as long as the removal area R1 is larger than the outer shape cutting area R2, but it may, for example, follow the shape of the outer shape cutting area R2. As will be described later, one example of the outer shape cutting area R2 is approximately circular, so the removal area R1 may also be approximately circular. In this case, the lower limit of the diameter of the removal area R1 may be, for example, the diameter of the outer shape cutting area R2 plus 0.2 mm, or the diameter of the outer shape cutting area R2 plus 0.5 mm, or the diameter of the outer shape cutting area R2 plus 1 mm. The upper limit of the diameter of the removal area R1 is a value that does not affect the processing of the strip metal sheet MS in the first to fifth processing units or the feeding of the strip metal sheet MS by the rollers 131 and 132. For example, it may be a value obtained by adding 10 mm to the diameter of the outer shape removal area R2, or a value obtained by adding 5 mm to the diameter of the outer shape removal area R2, or a value obtained by adding 2 mm to the diameter of the outer shape removal area R2.

[0072] The pressing member 123 is plate-shaped. The pressing member 123 is provided with a through hole 123a that penetrates in the direction of its thickness. The through hole 123a is located above the discharge hole 121a and below the irradiation unit 122. The size of the through hole 123a is set to be larger than the size of the removal area R1. When the irradiation unit 122 cuts the removal area R1 of the strip-shaped metal plate MS, the entire removal area R1 is located inside the through hole 123a when viewed from above. Note that the outer dimensions of the laminated core 1 also change depending on the type of laminated core 1. If the type of laminated core 1 to be manufactured is changed, the pressing member 123 may be replaced with one having a through hole 123a that corresponds to the size of the changed laminated core 1.

[0073] The pressing member 123 is configured to press the strip-shaped metal plate MS against the upper surface of the base 121 when the irradiation unit 122 irradiates the strip-shaped metal plate MS with laser light. As a result, the strip-shaped metal plate MS is sandwiched between the pressing member 123 and the base 121, so that the flapping of the strip-shaped metal plate MS is suppressed, and the laser light that has passed through the through hole 123a of the pressing member 123 is irradiated onto the strip-shaped metal plate MS. Therefore, fluctuations in the separation distance between the irradiation unit 122 and the strip-shaped metal plate MS are suppressed, and the strip-shaped metal plate MS is cut by the laser light while the focus of the laser light remains focused on the strip-shaped metal plate MS. Consequently, it is possible to cut the strip-shaped metal plate MS with extremely good precision.

[0074] The pressing member 123 may be connected to an actuator (not shown). The actuator may be configured to move the pressing member 123 closer to and further away from the upper surface of the base 121 based on instruction signals from the controller Ctr.

[0075] The cutting blade 124 is positioned downstream of the base 121 in the feeding direction and above the strip-shaped metal plate MS. The cutting blade 124 is configured to cut the strip-shaped metal plate MS at a predetermined timing. The cutting blade 124 may be connected to an actuator (not shown). The actuator may be configured to move the cutting blade 124 closer to and further away from the strip-shaped metal plate MS based on an instruction signal from the controller Ctr. Alternatively, the strip-shaped metal plate MS may be cut by an operator at a predetermined timing instead of the cutting blade 124.

[0076] The suction unit 125 is located in the discharge hole 121a of the base 121. The suction unit 125 operates based on instruction signals from the controller Ctr and is configured to adsorb the lower surface of the strip-shaped metal plate MS when the irradiation unit 122 cuts the strip-shaped metal plate MS. The suction unit 125 may be, for example, a vacuum chuck or an electromagnet. After the irradiation unit 122 cuts the strip-shaped metal plate MS, the suction unit 125 may release the adsorption of the cut piece from the strip-shaped metal plate MS and drop the cut piece into the discharge hole 121a. In this case, the cut piece is discharged to the outside of the laser device 120 through the discharge hole 121a.

[0077] The detection unit SE2 is configured to detect the presence or absence of a defect M on the strip-shaped metal plate MS. The detection unit SE2 is located upstream of the irradiation unit 122 in the delivery direction. That is, the detection unit SE2 is configured to detect the defect M on the strip-shaped metal plate MS before it reaches the press working apparatus 200. The detection unit SE2 is configured to transmit the presence or absence of the detection of the defect M to the controller Ctr. The detection unit SE2 is not particularly limited as long as it can detect the defect M, but may be a non-contact sensor such as a laser distance sensor, photoelectric sensor, or image sensor.

[0078] The detection unit SE3 is configured to detect the position of the lower die 210A in the delivery direction. The detection unit SE3 may also be configured to detect, for example, the separation distance of the lower die 210A from the base 121. In the example in Figure 4, the detection unit SE3 detects the shortest distance between the downstream end face 121b of the base 121 in the delivery direction and the upstream end face 212a of the die holder 212 in the delivery direction. In this case, the detection unit SE3 may be attached to the end face 121b of the base 121. The detection unit SE3 is configured to transmit the detected position (separation distance) of the lower die 210A to the controller Ctr. The detection unit SE3 is not particularly limited as long as it can detect the position (separation distance) of the lower die 210A, but may be a non-contact sensor such as a laser distance sensor, photoelectric sensor, or image sensor. Alternatively, instead of the detection unit SE3, an operator may measure the position (separation distance) of the lower die 210A and input the measurement result to the controller Ctr.

[0079] [Manufacturing method for laminated iron cores] (A) If defect M is not detected Next, with reference to Figures 5 to 7, a method for manufacturing the laminated iron core 1 when no defects M are detected in the strip-shaped metal plate MS will be described.

[0080] First, as illustrated in Figure 5, when the strip metal sheet MS is intermittently fed into the press working device 200 by rollers 131 and 132, the outer shape cutting area R2 of the strip metal sheet MS reaches the first processing unit. Next, the press machine 230 operates and pushes the upper part 220 downward toward the lower part 210. Even after the stripper 222 reaches the strip metal sheet MS and the strip metal sheet MS is clamped between the stripper 222 and the die member 213, the press machine 230 continues to push the upper part 220 downward.

[0081] At this time, the stripper 222 does not move, but the punch holder 221 and punches P1 to P5 continue to descend. As a result, the tips of punches P1 to P5 move downward through the respective through holes of the stripper 222 and further reach the die holes D1a to D5a. In this process, punch P1 punches out the strip metal plate MS along the die hole D1a (see Figures 5 and 6). This creates a positioning hole H1 in the strip metal plate MS (see Figure 7). The punched-out waste material is discharged from the discharge hole C1. After that, the press machine 230 operates and raises the upper part 220.

[0082] Next, the strip metal sheet MS is intermittently fed by rollers 131 and 132 by one pitch (distance d), and the outer shape cutting area R2 of the strip metal sheet MS reaches the second processing unit. Then, similarly to the above, the upper part 220 is moved up and down by the press machine 230, and the strip metal sheet MS is punched out by the punch P2 and die D2 (see Figures 5 and 6). As a result, through holes H2 corresponding to the slots 6 of the laminated iron core 1 are formed in the strip metal sheet MS (see Figure 7). The punched waste material is discharged from the discharge hole C2.

[0083] Next, the strip metal sheet MS is intermittently fed by rollers 131 and 132 by one pitch (distance d), and the outer shape cutting area R2 of the strip metal sheet MS reaches the third processing unit. Then, similarly to the above, the upper part 220 is moved up and down by the press machine 230, and the strip metal sheet MS is processed by the punch P3 and die D3 (see Figures 5 and 6). As a result, depending on the position of the cam member 223a in the switching device 223 (first position and second position), either the uneven part (processed part H3) corresponding to the crimp 5a of the joint 5 or the through hole (processed part H3) corresponding to the through hole 5b of the joint 5 is selectively formed on the strip metal sheet MS (see Figure 7). The waste material punched out during the formation of the through hole is discharged from the discharge hole C3.

[0084] Next, the strip metal sheet MS is intermittently fed by rollers 131 and 132 by one pitch (distance d), and the outer shape cutting area R2 of the strip metal sheet MS reaches the fourth processing unit. Then, similarly to the above, the upper part 220 is moved up and down by the press machine 230, and the strip metal sheet MS is punched out by the punch P4 and die D4 (see Figures 5 and 6). As a result, a through hole H4 corresponding to the central hole 1a of the laminated iron core 1 is formed in the strip metal sheet MS (see Figure 7). The punched waste material is discharged from the discharge hole C4.

[0085] Next, the strip metal sheet MS is intermittently fed forward by rollers 131 and 132 by 1 pitch (distance d), and the outer shape cutting area R2 of the strip metal sheet MS reaches the fifth processing unit. Then, similarly to the above, the upper part 220 is moved up and down by the press machine 230, and the strip metal sheet MS is punched out by the punch P5 and die D5 (see Figures 5 and 6). As a result, if the uneven portion corresponding to the crimp 5a of the joint 5 is formed in the outer shape cutting area R2, the punched member W (see Figure 7) punched out from the strip metal sheet MS by the fifth punching unit is stacked with the previously punched punched member W, fastened together by the crimp 5a. On the other hand, if a through-hole corresponding to the through-hole 5b of the joint 5 is formed in the outer shape punching region R2, the punched member W (see Figure 7) punched out from the strip metal sheet MS by the fifth punching unit is not fastened to the crimp 5a of the previously punched punched member W, but is placed on top of the previously punched punched member W. As a result, the lamination of a group of punched members W is completed within the die hole D5a and the squeeze ring Q, and the laminated iron core 1 is completed by this group of punched members W. The completed laminated iron core 1 is placed on the transport mechanism 215 through the discharge hole C5 and transported out of the press working device 200 by the transport mechanism 215.

[0086] Incidentally, when the strip metal sheet MS is punched by the fifth processing unit, the controller Ctr adds "1" to the number of layers of punched material W stacked in the die hole D5a and squeeze ring Q. Furthermore, when the outer shape punching region R2 of the strip metal sheet MS, in which the through hole corresponding to the through hole 5b was formed in the third processing unit, is punched out by the fifth processing unit, the controller Ctr resets the number of layers of punched material W to "1" and starts counting again.

[0087] When the outer shape cutting area R2 of the strip metal plate MS reaches the third processing unit, the controller Ctr determines whether the number of layers (actual number of layers) of the laminate in the die hole D5a and squeeze ring Q will exceed a predetermined number of layers (set number of layers) when the outer shape cutting area R2 is punched out in the fifth processing unit. If the controller Ctr determines that the actual number of layers does not exceed the set number of layers, it controls the switching device 223 to position the cam member 223a to the second position. As a result, when the outer shape cutting area R2 reaches the third processing unit, the recessed portion corresponding to the crimp 5a is formed in the outer shape cutting area R2. On the other hand, if the controller Ctr determines that the actual number of layers exceeds the set number of layers, it controls the switching device 223 to position the cam member 223a to the first position. As a result, when the outer shape cutting area R2 reaches the third processing unit, the through hole corresponding to the through hole 5b is formed in the outer shape cutting area R2. In addition, in the press working apparatus 200 illustrated in Figures 5 and 6, since the third processing unit is located two processes before the fifth processing unit, the controller Ctr may determine whether the number of layers of the laminate in the die hole D5a and squeeze ring Q (actual number of layers) exceeds the set number of layers minus 2 (set number of layers - 2) when the outer shape punching area R2 of the strip metal sheet MS reaches the fifth processing unit and is punched out.

[0088] (B) When a defect M is detected Next, with reference to Figures 4, 5, and 8-12, a method for manufacturing the laminated iron core 1 when a defect M is detected in the strip-shaped metal plate MS will be described. In this document, the detection of the defect M by the detection unit SE2 includes both direct detection of the defect M by the detection unit SE2 and indirect detection of the defect M by the detection unit SE2 detecting an index attached to the strip-shaped metal plate MS corresponding to the defect M. Figures 8-12 illustrate an example where the defect M is a welded portion extending in the width direction of the strip-shaped metal plate MS.

[0089] First, as illustrated in Figure 4, when the detection unit SE2 detects a defect M, the controller Ctr instructs the irradiation unit 122 to cut the strip metal plate MS along the contour of the removal area R1 so as to include the entire outer shape removal area R2 when the defect M reaches below the irradiation unit 122. This forms a through hole G in the strip metal plate MS with a shape corresponding to the removal area R1 (see Figure 5). Subsequently, as the strip metal plate MS is intermittently fed to the press working device 200 by rollers 131 and 132, the through hole G reaches the first processing unit (see Figure 8).

[0090] Next, the strip-shaped metal plate MS is intermittently fed forward by rollers 131 and 132 by one pitch (distance d), and the through-hole G reaches the second processing unit (see Figure 9). At this time, due to the presence of the through-hole G, the punch P2 passes through the through-hole G without contacting the strip-shaped metal plate MS (it dries out). In other words, the punch P2 does not punch through the defective part M.

[0091] Next, the strip-shaped metal plate MS is intermittently fed forward by rollers 131 and 132 by one pitch (distance d), and the through-hole G reaches the third processing unit (see Figure 10). At this time, due to the presence of the through-hole G, the punch P3 passes through the through-hole G without contacting the strip-shaped metal plate MS (it dries out). In other words, the punch P3 does not punch through the defective part M.

[0092] Next, the strip metal plate MS is intermittently fed forward by rollers 131 and 132 by one pitch (distance d), and the through hole G reaches the fourth processing unit (see Figure 11). At this time, due to the presence of the through hole G, the punch P4 passes through the through hole G without contacting the strip metal plate MS (it dries out). In other words, the punch P4 does not punch through the defective part M.

[0093] Next, the strip metal plate MS is intermittently fed forward by rollers 131 and 132 by one pitch (distance d), and the through hole G reaches the fifth processing unit (see Figure 12). At this time, due to the presence of the through hole G, the punch P5 passes through the through hole G without contacting the strip metal plate MS (it dries out). In other words, the punch P5 does not punch through the defective part M.

[0094] [Position correction of the irradiation area] (A) In the case of positional misalignment caused by the relative position between the irradiation position of the laser beam from the irradiation unit 122 and the outer shape cutting area R2. Next, referring to Figures 4 and 13, a method for correcting the amount of misalignment δ1 in the transmission direction when there is a positional misalignment caused by the relative position between the irradiation position of the laser beam from the irradiation unit 122 and the outer shape cutting area R2 will be explained.

[0095] First, when a through hole G is formed in the strip metal plate MS by the irradiation unit 122, the detection unit SE1 detects the position of the through hole G in the strip metal plate MS in the feeding direction, as illustrated in Figure 5. The controller Ctr calculates the amount of displacement δ1 of the through hole G in the feeding direction (see Figure 13) based on the position detected by the detection unit SE1. The amount of displacement δ1 may be the magnitude of the displacement of the through hole G in the feeding direction relative to the value obtained by multiplying the feed pitch (distance d) by an integer N (N × d). The integer N is the number of times the strip metal plate MS is intermittently fed before the outer shape cutting region R2 located in the irradiation unit 122 reaches the fifth processing unit.

[0096] Next, the controller Ctr determines whether the calculated displacement amount δ1 is within a predetermined tolerance range. This predetermined range may be, for example, approximately ±0.2 mm or approximately ±0.1 mm. If the controller Ctr determines that the displacement amount δ1 is within the tolerance range, it continues punching out the punched member W from the strip metal plate MS (manufacturing of the laminated iron core 1) without correcting the displacement amount δ1.

[0097] On the other hand, if the controller Ctr determines that the displacement amount δ1 is outside the allowable range, the controller Ctr instructs the irradiation unit 122 to shift the irradiation position of the laser beam from the irradiation unit 122 by the displacement amount δ1 in the delivery direction. As a result, the displacement amount δ1 of the irradiation position of the laser beam from the irradiation unit 122 is corrected, and the subsequent through hole G is formed to include the entire outer shape cutout region R2. Note that the correction of the irradiation position of the laser beam from the irradiation unit 122 may be done by changing the irradiation angle of the laser beam irradiated from the irradiation unit 122 toward the strip-shaped metal plate MS, or by changing the position of the irradiation unit 122 itself.

[0098] (B) In the case of misalignment caused by displacement of the lower mold 210A Next, referring to Figure 14, a method for correcting the displacement amount δ2 in the delivery direction when there is a positional displacement caused by the displacement of the lower die 210A will be explained.

[0099] First, as illustrated in Figure 14, the detection unit SE3 detects the position of the lower die 210A in the feeding direction. Based on the position detected by the detection unit SE3, the controller Ctr calculates the displacement amount δ2 of the fifth processing unit (die D5) in the feeding direction (see Figure 14).

[0100] Here, the displacement δ2 can also be calculated as follows. First, the parameters L0, L1, and L3 are respectively L0: The straight-line distance between the end face 121b of the base 121 and the end face 212a of the die holder 212 in the delivery direction, as measured by the detection unit SE3. L1: The straight-line distance between the end face 121b of the base 121 and the center of the through hole G formed in the strip-shaped metal plate MS by the irradiation unit 122 in the delivery direction. L2: Straight-line distance between the end face 212a of the die holder 212 and the center of the die hole D5a of the die D5 in the feeding direction. This is defined as follows. Therefore, if the lower die 210A is not displaced in the feeding direction (when the displacement amount δ2 is approximately 0), L0 + L1 + L2 will be approximately equal to the value obtained by multiplying the feed pitch (distance d) by an integer N (N × d).

[0101] Here, the linear distance L1 does not change unless the irradiation position of the laser beam by the irradiation unit 122 is corrected. The linear distance L2 does not change because the die D5 is installed in the die holder 212 via the die plate 213a. In this way, since the linear distances L1 and L2 are defined as nearly fixed values, the linear distance L3 can be accurately measured by the detection unit SE3.

[0102] On the other hand, if the lower die 210A is displaced in the feed direction (i.e., the displacement amount δ2 is not 0), then L0 + L1 + L2 will be a value that is shifted by the displacement amount δ2 from the value obtained by multiplying the feed pitch (distance d) by an integer N (N × d). In other words, the controller Ctr calculates the displacement amount δ2 by subtracting N × d from L0 + L1 + L2.

[0103] Next, the controller Ctr determines whether the calculated displacement amount δ1 is within a predetermined tolerance range. This predetermined range may be, for example, approximately ±0.2 mm or approximately ±0.1 mm. If the controller Ctr determines that the displacement amount δ1 is within the tolerance range, it continues punching out the punched member W from the strip metal plate MS (manufacturing of the laminated iron core 1) without correcting the displacement amount δ1.

[0104] On the other hand, if the controller Ctr determines that the displacement amount δ2 is outside the allowable range, the controller Ctr instructs the irradiation unit 122 to shift the irradiation position of the laser beam from the irradiation unit 122 by the displacement amount δ2 in the delivery direction. As a result, the displacement amount δ2 of the irradiation position of the laser beam from the irradiation unit 122 is corrected, and the subsequent through hole G is formed to include the entire outer shape cutout region R2. Note that the correction of the irradiation position of the laser beam from the irradiation unit 122 may be done by changing the irradiation angle of the laser beam irradiated from the irradiation unit 122 toward the strip-shaped metal plate MS, or by changing the position of the irradiation unit 122 itself.

[0105] The correction of the displacement amount δ2 may be performed, for example, after the lower die 210A and punch holder 221 are replaced from the press working device 200 due to a change in the type of laminated core 1 being manufactured. Alternatively, the correction of the displacement amount δ2 may be performed, for example, after the defect M is detected by the detection unit SE2 (including the time when the defect M is detected by the detection unit SE2).

[0106] (C) Control when the deviation amounts δ1 and δ2 are outside the acceptable range If the controller Ctr determines that the displacement amounts δ1 and δ2 are outside the acceptable range, it may control the cutting blade 124 to cut the strip metal sheet MS so that the strip metal sheet MS separates in the feeding direction. The controller Ctr may also cut the strip metal sheet MS after it has been fed out until the through hole G is located downstream of the cutting blade 124. In this case, the through hole G will be located at the downstream end of the leading strip metal sheet MS of the separated strip metal sheet MS. In other words, the trailing strip metal sheet MS of the separated strip metal sheet MS will not have a through hole G. Therefore, when feeding the trailing strip metal sheet MS into the press working device 200, handling of the trailing strip metal sheet MS becomes easier, making it possible to perform the feeding operation efficiently. For the leading strip metal sheet MS of the separated strip metal sheet MS, punching of the punched member W (manufacturing of the laminated iron core 1) may be continued until the through hole G reaches the fifth processing unit. When the strip metal sheet MS is cut by the cutting blade 124, the entire manufacturing apparatus 100 may be stopped in order to pass the trailing strip metal sheet MS through the press working apparatus 200.

[0107] [Counting process for the number of layers in a laminated iron core] (A) Counting the number of layers in the laminated core 1 when the through hole G reaches the fifth processing unit. As illustrated in Figure 12, when the through-hole G reaches the fifth processing unit and a punching operation is performed in the fifth processing unit, the presence of the through-hole G causes the punch P5 to be misfired, and the punched member W is not punched out from the strip metal plate MS. Therefore, in this case, the controller Ctr does not need to add "1" to the number of layers of punched member W stacked in the die hole D5a and squeeze ring Q. Not adding "1" to the number of layers of punched member W may also include, for example, adding "1" to the number of layers of punched member W when a punching operation is performed in the fifth processing unit, while subtracting "1" from the number of layers of punched member W when a misfire of the punch P5 is detected by a detection unit (not shown) or the like.

[0108] Furthermore, if the controller Ctr determines that the displacement amounts δ1 and δ2 are outside the acceptable range and the strip metal sheet MS is cut by the cutting blade 124, it may stop counting the number of stacked punched members W until the trailing strip metal sheet MS of the separated strip metal sheet MS is passed through the press working device 200 and reaches the fifth processing unit.

[0109] (B) Counting process of the number of layers in the laminated core 1 when the through hole G reaches the third processing unit. As illustrated in Figure 10, when the through-hole G reaches the third processing unit and the cam member 223a is in the first position in the switching device 223, the presence of the through-hole G causes the punch P3 to be struck empty, and the through-hole corresponding to the through-hole 5b is not formed in the strip metal plate MS. Therefore, at this time, the controller Ctr may control the switching device 223 after the through-hole G has passed through the third processing unit to maintain the state in which the cam member 223a is in the first position. This prevents the punched member W, which has a recessed portion corresponding to the crimp 5a formed on it, from being punched out in the fifth processing unit and fastened to the crimp 5a of the punched member W that was punched out earlier, even though the actual number of layers has reached the set number of layers.

[0110] [Effect] In the above example, when a defect M is detected by the detection unit SE2, a removal area R1, which is set to be larger than the size of the outer shape punching area R2, is removed from the strip metal plate MS. As a result, the defect M is removed from the part of the strip metal plate MS corresponding to the removal area R1, and a through hole G for blank punching is formed in the strip metal plate MS. Therefore, when the removal area R1 of the strip metal plate MS reaches the fifth processing unit (outer shape punching section), the strip metal plate MS is not punched out by the fifth processing unit due to the presence of the through hole G. As a result, the part of the strip metal plate MS containing the defect M does not become the punched member W, so it is possible to remove the defect M present in the strip metal plate MS and eliminate the impact of the defect M on the product (laminated iron core 1).

[0111] As shown in the above example, even if there is a misalignment in the irradiation position of the laser beam from the irradiation unit 122 of the laser device 120, and the formation position of the through-hole G is misaligned in the delivery direction, the processing of the strip metal sheet MS by the press working device 200 will continue as long as the amount of misalignment δ1 of the through-hole G is within the allowable range. Therefore, when the removal area R1 of the strip metal sheet MS reaches the fifth processing unit, it is unlikely that the fifth processing unit will punch out the area near the periphery of the through-hole G. Consequently, the presence of the through-hole G more reliably suppresses punching out of the strip metal sheet MS by the fifth processing unit. As a result, it becomes possible to more effectively eliminate the impact of defects M on the product (laminated iron core 1).

[0112] As shown in the above example, if there is a positional misalignment in the irradiation position of the laser beam by the irradiation unit 122 of the laser device 120, and the formation position of the through-hole G is misaligned in the delivery direction, the amount of misalignment δ1 of the through-hole G is corrected. Therefore, even if there is a positional misalignment in the irradiation position of the laser beam by the irradiation unit 122 of the laser device 120, it becomes possible to further eliminate the impact of the defect M on the product (laminated iron core 1).

[0113] In the above example, the detection unit SE1 is provided on the end face 212a of the die holder 212 and is properly fixed to the lower mold 210A. Therefore, it is possible to improve the detection accuracy of the position of the through hole G by the detection unit SE1.

[0114] As shown in the above example, even if the position of the lower mold 210A (the position of the fifth processing unit) is misaligned with respect to the irradiation unit 122 of the laser device 120, the irradiation position of the laser beam from the irradiation unit 122 is corrected according to the amount of misalignment δ2. Therefore, even if there is a misalignment in the lower mold 210A, it becomes possible to further eliminate the influence of the defect M on the product (laminated iron core 1).

[0115] Incidentally, the molds (including the lower mold 210A) of the press working apparatus 200 are changed depending on the type and size of the product to be manufactured (laminated iron core 1). During this change, the position of the lower mold 210A (the position of the fifth processing unit) may shift relative to the irradiation unit 122 of the laser device 120. Also, when the press working apparatus 200 is in operation, vibrations are generated due to the vertical movement of the mold (punch holder 221). Due to these vibrations, the position of the lower mold 210A may shift relative to the irradiation unit 122 of the laser device 120. However, as shown in the above example, the amount of shift δ2 is corrected after the lower mold 210A is changed or after the defect M is detected by the detection unit SE2. Therefore, even if the lower mold 210A shifts position due to mold change or vibration, it becomes possible to further eliminate the impact of the defect M on the product (laminated iron core 1).

[0116] As shown in the above example, the shape of the removal area R1 is set to conform to the shape of the outer shape cutting area R2. Therefore, the removal area R1 removed from the strip metal sheet MS can be set to the minimum. Consequently, when punching out the upstream or downstream portion of the removal area R1 of the strip metal sheet MS by the fifth processing unit, the punching of that portion by the fifth processing unit is less likely to interfere with the through hole G. As a result, it is not necessary to provide a large clearance between the through hole G and the outer shape cutting areas R2 located before and after it in order to avoid such interference, so it is possible to make efficient use of the strip metal sheet MS without waste while eliminating the impact of defects M on the product (laminated iron core 1).

[0117] As shown in the above example, when the punched member W is not punched out from the strip metal plate MS by the fifth processing unit due to the presence of the through hole G, it is not counted as part of the number of layers of punched member W. Therefore, it is possible to manufacture laminated core 1 (laminated body 2) with the correct number of layers.

[0118] Incidentally, when a crimp 5a is formed on the strip-shaped metal plate MS, and the punched member W is punched out together with the crimp 5a in the fifth processing unit, the punched member W is fastened to the previously punched-out member W via the crimp 5a, and thus becomes part of the previously formed laminate 2. On the other hand, when a through hole 5b is formed on the strip-shaped metal plate MS, and the punched member W is punched out together with the through hole 5b in the fifth processing unit, the punched member W is not fastened to the previously punched-out member W, and thus becomes part of a new laminate 2 independently of the previously formed laminate 2. In other words, when a punched member W with a through hole 5b is punched out from the strip-shaped metal plate MS, the lamination of the punched member W onto the previously formed laminate 2 is completed, the laminate 2 is completed as a laminated iron core 1, and the manufacturing of a new laminate 2 is started from the punched member W with the through hole 5b. Therefore, if the through-hole G reaches the third processing unit (switching device 223) and the formation of the through-hole 5b in the outer shape cutting region R2 is selected, the punched member W with the through-hole 5b will not be laminated onto the laminate 2 which has already been laminated, and the subsequent punched member W with the crimp 5a formed will be laminated onto the laminate 2, resulting in the production of a laminate 2 with more punched members W than the set number of layers. However, in the above example, when the through-hole G reaches the third processing unit (switching device 223) and the formation of the through-hole 5b in the outer shape cutting region R2 is selected, the formation of the through-hole 5b in the outer shape cutting region R2 is selected again after passing through the through-hole G. As a result, the punched member W with the through-hole 5b will be laminated onto the laminate 2 which has already been laminated. Therefore, even if the strip metal plate MS has a through-hole G formed in it, it is possible to manufacture a laminate 2 with the set number of layers.

[0119] [Differentiation] The disclosures herein should be considered in all respects to be illustrative and not restrictive. Various omissions, substitutions, and modifications may be made to the above examples without departing from the claims and the gist thereof.

[0120] (1) As illustrated in Figure 15, the detection unit SE1 may be provided on the laser device 120 so as to be located downstream of the irradiation unit 122 in the delivery direction. In this case, the detection unit SE1 can be properly fixed to the laser device 120. This makes it possible to improve the accuracy of detection of the position of the through hole G by the detection unit SE1.

[0121] (2) As illustrated in Figure 16, the detection unit SE3 may be attached to the bolster 211 (for example, the top surface or end surface of the bolster 211). In this case as well, the detection unit SE3 may detect the position of the lower die 210A in the delivery direction (in the example of Figure 16, the position of the end surface 212a of the die holder 212 in the delivery direction). In the example of Figure 16, when the detection unit SE3 detects the position, it may detect the displacement of the position of the lower die 210A in the delivery direction with respect to a reference position provided on the bolster 211 as a displacement amount δ2.

[0122] (3) As illustrated in Figure 17, the press working apparatus 200 may further include a detection unit SE4. In this case, in addition to the detection unit SE3 detecting the position of the lower die 210A in the feeding direction, the detection unit SE4 may detect the position of the lower die 210A in the width direction. Based on the positions detected by the detection units SE3 and SE4, the irradiation position of the laser beam by the irradiation unit 122 may be corrected.

[0123] (4) As illustrated in Figure 18, the strip metal plate MS may be provided with through holes J (detection through holes) different from the through holes G and positioning holes H1. The through holes J may be located corresponding to the through holes G, or for example, in the vicinity of the through holes G. The through holes J may be located in a position that does not affect the processing of the strip metal plate MS in the first to fifth processing units. The through holes J may be formed, for example, by the irradiation unit 122 of the laser device 120. The through holes J may be formed, for example, by irradiating the strip metal plate MS with laser light from an irradiation unit other than the irradiation unit 122. The through holes J may be formed, for example, by a processing unit for forming the through holes J, which consists of a punch and a die. The processing unit for forming the through holes J may be provided in the laser device 120.

[0124] The detection unit SE1 may be configured to detect the position of the through-hole J in the delivery direction instead of the through-hole G. In this case, the detection unit SE1 detects the through-hole J provided in the strip-shaped metal plate MS, and the position of the through-hole G is detected via the position of the through-hole J. Therefore, by appropriately setting the formation position of the through-hole J on the strip-shaped metal plate MS, it is possible to increase the degree of freedom in the placement of the detection unit SE1 for detecting the position of the through-hole J.

[0125] If a through hole J is provided in the strip-shaped metal plate MS, instead of the detection unit SE1, a detection pin B10, as illustrated in Figure 19, may be used to determine whether the displacement amount δ1 is within the allowable range. The detection pin B10 may be attached to the punch holder 221, for example, via a biasing member B10a.

[0126] As illustrated in Figure 19(a), if the tip of the detection pin B10 is inserted into the through hole J, it may be determined that the displacement amount δ1 is within the acceptable range. On the other hand, as illustrated in Figure 19(b), if the tip of the detection pin B10 is not inserted into the through hole J, it may be determined that the displacement amount δ1 is outside the acceptable range.

[0127] (5) In the example shown in Figure 5, the amount of protrusion of the tip of the punch P3 was changed by the switching device 223 to selectively form either a recessed portion corresponding to the crimp 5a or a through-hole corresponding to the through-hole 5b on the strip metal sheet MS. However, by changing the amount of protrusion of the tip of the punch P3 by the switching device 223, either forming a through-hole corresponding to the through-hole 5b on the strip metal sheet MS or not processing the strip metal sheet MS with the punch P3 may be selectively performed. In this case, the press working apparatus 200 may further include a processing unit consisting of a punch and a die for forming a recessed portion corresponding to the crimp 5a on the strip metal sheet MS.

[0128] The processing unit may be located upstream or downstream of the switching device 223 (third processing unit). If the processing unit is located upstream of the switching device 223 (third processing unit), and the setting is such that the strip metal plate MS is not processed by the switching device 223 (third processing unit), the unevenness formed on the strip metal plate MS by the processing unit is maintained. On the other hand, if the setting is such that a through hole corresponding to the through hole 5b is formed by the switching device 223 (third processing unit), the unevenness formed on the strip metal plate MS by the processing unit is punched out by the third processing unit, and a through hole is formed on the strip metal plate MS in place of the unevenness.

[0129] If the processing unit is located downstream of the switching device 223 (third processing unit), and the setting is such that the strip metal plate MS is not processed by the switching device 223 (third processing unit), then the processing unit will form irregularities on the strip metal plate MS. On the other hand, if the setting is such that the switching device 223 (third processing unit) is configured to form a through hole corresponding to the through hole 5b, then the punch of the processing unit will strike the through hole empty, and therefore no irregularities will be formed on the strip metal plate MS.

[0130] (6) When the laser beam is irradiated onto the strip metal plate MS by the irradiation unit 122 and a through hole G is formed in the strip metal plate MS, thermal travel occurs in the peripheral area of ​​the strip metal plate MS where the through hole G is located (for example, an area extending approximately the thickness of the strip metal plate MS from the edge of the through hole G). As a result, changes occur in the peripheral area, such as the strip metal plate MS taking on a different color than other parts, or the composition of the strip metal plate MS (crystal shape, number, size, etc.) changing. Therefore, the punched member W punched out from the outer shape punching region R2 before and after the through hole G in the strip metal plate MS may have a slight thermal travel near its outer edge. However, since the thermal travel present in the punched member W is only in a very small area near its outer edge, even if the laminated iron core 1 is manufactured using the punched member W, it will have virtually no effect on the magnetic properties of the motor. Furthermore, by separating the outer shape punching regions R2 before and after the through hole G in the strip-shaped metal plate MS from the through hole G by a predetermined length (for example, a length approximately equal to the thickness of the strip-shaped metal plate MS) or more in the feeding direction, it is possible to prevent heat travel due to the laser beam from remaining in the punched member W.

[0131] (7) When manufacturing a product by punching out a strip-shaped member (strip-shaped material), the technology of this disclosure can be applied without being limited to the material of the strip-shaped member, as long as the defect M of the strip-shaped member can affect the product. The material of the strip-shaped member may be, for example, a metal plate (including electrical steel plate) or a resin material (for example, a resin film). When joining the ends of the strip-shaped members, various means such as welding, adhesive sheets such as tape, and adhesives can be used depending on the material of the strip-shaped member. In other words, the technology of this disclosure is applicable to all products manufactured by punching out a strip-shaped material that has defects including a defect M.

[0132] [Other examples] Example 1. An example of a manufacturing method for a processed product includes: a first step of detecting a defect in a strip-shaped member that is sent out in a predetermined direction by a feeding device before the defect reaches the press working device; a second step of removing a predetermined removal area from the strip-shaped member, which includes at least a part of the defect and is subject to punching out by the outer shape punching section of the press working device, by cutting the removal area with laser light emitted from the irradiation section of a laser device located upstream of the press working device in the feeding direction of the strip-shaped member, thereby forming a through hole for blank punching in the removal area of ​​the strip-shaped member; and a third step of punching out the outer shape punching area of ​​the strip-shaped member where the removal area has not been formed by the outer shape punching section to form a processed product. The size of the removal area is set to be larger than the size of the outer shape punching area.

[0133] In this case, if a defect is detected by the detection unit, a removal area larger than the size of the outer shape punching area is removed from the strip-shaped member. As a result, the defect is removed from the portion of the strip-shaped member corresponding to the removal area, and a through-hole for blank punching is formed in the strip-shaped member. Therefore, when the removal area of ​​the strip-shaped member reaches the outer shape punching area, the strip-shaped member is not punched out by the outer shape punching area due to the presence of the through-hole for blank punching. As a result, the portion of the strip-shaped member containing the defect does not become a processed product, making it possible to remove the defect present in the strip-shaped member and eliminate the impact of the defect on the product.

[0134] Example 2. The method of Example 1 may further include a fourth step of detecting the position of the blank-firing through-hole formed in the strip-shaped member in the delivery direction using another detection unit; a fifth step of calculating the amount of displacement of the blank-firing through-hole in the delivery direction based on the position detected by the other detection unit; a sixth step of determining whether the amount of displacement of the blank-firing through-hole is within a predetermined allowable range; and a seventh step of continuing the processing of the strip-shaped member by the press working device if the amount of displacement of the blank-firing through-hole is within the allowable range. In this case, even if there is a positional displacement in the irradiation position of the laser beam by the irradiation unit of the laser device, and the formation position of the blank-firing through-hole is shifted in the delivery direction, the processing of the strip-shaped member by the press working device is continued if the amount of displacement of the blank-firing through-hole is within the allowable range. Therefore, when the removal area of ​​the strip-shaped member reaches the outer shape punching section, it is less likely that the outer shape punching section will punch out the vicinity of the periphery of the blank-firing through-hole, and thus the presence of the blank-firing through-hole more reliably suppresses punching out of the strip-shaped member by the outer shape punching section. Therefore, it becomes possible to further eliminate the impact of defects on the product.

[0135] Example 3. The method of Example 2 may further include an eighth step in which, if the amount of misalignment of the through-hole for dummy firing is outside the allowable range, the irradiation position of the laser beam from the irradiation unit is corrected in the delivery direction according to the amount of misalignment of the through-hole for dummy firing. In this case, if there is a positional misalignment in the irradiation position of the laser beam by the irradiation unit of the laser device, and the formation position of the through-hole for dummy firing is misaligned in the delivery direction, the amount of misalignment of the through-hole for dummy firing is corrected. Therefore, even if there is a positional misalignment in the irradiation position of the laser beam by the irradiation unit of the laser device, the same effects as in Example 2 can be obtained.

[0136] Example 4. In either Example 2 or Example 3, the other detection unit may be provided on the laser device so as to be located downstream of the irradiation unit in the delivery direction, or on the upstream end face in the delivery direction of the lower die of the press working device. In this case, the other detection unit can be appropriately fixed to the laser device or the lower die. This makes it possible to improve the accuracy of detecting the position of the through-hole for dry firing by the other detection unit.

[0137] Example 5. In any of the methods in Examples 2 to 4, another detection unit may be configured to detect detection through holes provided in the strip-shaped member. In this case, the position of the dry-firing through hole is detected via the position of the detection through hole by the other detection unit detecting the detection through hole provided in the strip-shaped member. Therefore, by appropriately setting the formation position of the detection through hole on the strip-shaped member, it is possible to increase the degree of freedom in arranging the other detection unit for detecting the position of the detection through hole.

[0138] Example 6. In the method of Example 5, the detection through-hole may be a through-hole for dry firing, or a through-hole formed separately from the dry firing through-hole in the strip-shaped member.

[0139] Example 7. Any of the methods in Examples 1 to 6 may further include a ninth step of detecting the position of the lower die of the press working apparatus in the feed direction by another detection unit, a tenth step of calculating the amount of displacement of the outer shape punching section in the feed direction based on the position detected by the other detection unit, an eleventh step of determining whether the amount of displacement of the outer shape punching section is within a predetermined other allowable range, and a twelfth step of correcting the irradiation position of the laser beam from the irradiation unit in the feed direction according to the amount of displacement of the outer shape punching section if the amount of displacement of the outer shape punching section is outside the other allowable range. In this case, even if the position of the lower die (position of the outer shape punching section) is misaligned with respect to the irradiation unit of the laser device, the irradiation position of the laser beam from the irradiation unit is corrected according to the amount of misalignment. Therefore, even if there is a positional misalignment of the lower die (outer shape punching section), the same effects as in Example 2 can be obtained.

[0140] Example 8. In the method of Example 7, steps 9 to 12 may be performed after the lower die is replaced or after the detection unit detects a defect. Incidentally, the die (including the lower die) of the press working apparatus is replaced depending on the type and size of the product to be manufactured. During this replacement, the position of the lower die (position of the outer shape cutting area) may shift relative to the irradiation area of ​​the laser device. Also, when the press working apparatus is in operation, vibrations are generated due to the vertical movement of the die (upper die). Due to these vibrations, the position of the lower die (position of the outer shape cutting area) may shift relative to the irradiation area of ​​the laser device. However, according to Example 8, steps 9 to 12 of Example 7 are performed after the lower die is replaced or after the detection unit detects a defect. Therefore, even if a positional shift occurs in the lower die (outer shape cutting area) due to die replacement or vibration, the same effects as in Example 2 can be obtained.

[0141] Example 9. In any of the methods in Examples 1 to 8, the shape of the removal area may be a shape that follows the shape of the outer punching area. In this case, the removal area removed from the strip member can be set to a minimum. Therefore, when punching out the upstream or downstream portion of the removal area of ​​the strip member with the outer punching part, the punching of that portion by the outer punching part becomes less likely to interfere with the through-hole for blank punching. Consequently, it is not necessary to provide a large clearance between the through-hole for blank punching and the outer punching areas located before and after it in order to avoid such interference, so it is possible to make efficient use of the strip member without waste while eliminating the impact of defects on the product.

[0142] Example 10. Any of the methods in Examples 1 to 9 further includes a 13th step in which the processed products formed in the third step are stacked in the outer shape punching section to form a laminate, and the number of stacked processed products in the outer shape punching section is counted. The 13th step may also include not counting the number of stacked processed products when a blank punching through hole reaches the outer shape punching section and the strip member is punched out by the outer shape punching section. In this case, since the processed products are not counted as stacked products when they are not punched out from the strip member by the outer shape punching section, it is possible to manufacture a laminate with an accurate number of stacks.

[0143] Example 11. Any of the methods in Examples 1 to 10 further includes a 14th step of selectively forming either a crimp or a through hole in the outer shape punched area of ​​the strip member where no removal area has been formed, using a switching processing unit provided in a press working device, and a 15th step of stacking the processed products formed in the third step in the outer shape punched area to form a laminate, wherein the 14th step may include selecting again to form a through hole in the outer shape punched area after the blank through hole has passed through the switching processing unit, when the blank through hole has reached the switching processing unit and the formation of a through hole in the outer shape punched area has been selected. Incidentally, when a crimp is formed on the strip member, when the processed product is punched out together with the crimp in the outer shape punched area, the processed product is fastened to a previously punched processed product via the crimp, and thus becomes part of the laminate that was previously formed. On the other hand, if a through-hole is formed in the strip-shaped member, and the processed product is punched out along with the through-hole in the outer shape punching section, the processed product will not be fastened to the previously punched-out processed product. Therefore, it will become part of a new laminate, independent of the previously formed laminate. In other words, when a processed product with a through-hole is punched out from the strip-shaped member, the lamination of the processed product onto the previously formed laminate is completed, and the manufacturing of a new laminate begins from the processed product with the through-hole. Consequently, if the blank-punching through-hole reaches the switching processing section and the selection is made to form a through-hole in the outer shape punching area, the processed product with the through-hole will not be laminated onto the laminate that has already been laminated, and the subsequent processed product with rivet formed will be laminated onto the laminate, resulting in the production of a laminate with more processed products than the set number of layers. However, according to Example 11, when the blank-firing through-hole reaches the switching processing section and it is selected to form a through-hole in the outer shape cutting region, it is again selected to form a through-hole in the outer shape cutting region after passing through the blank-firing through-hole. Therefore, the processed product with the formed through-hole is laminated to the laminate that has already been laminated. Thus, even if a blank-firing through-hole is formed in the strip-shaped member, it is possible to manufacture a laminate with a set number of layers. [Explanation of Symbols]

[0144] 1…Laminated iron core, 2…Laminate, 5…Joint, 5a…Crimping, 5b…Through hole, 100…Laminated iron core manufacturing equipment, 120…Laser device, 122…Irradiation unit, 130…Feeding device, 131,132…Roller, 200…Pressing device, 210A…Lower die, 212…Die holder (mold, lower die), 212a…End face, 213…Die component, 213a…Die plate (mold, lower die), 221…Punch holder (upper die, mold), 223…Switching device (switching processing unit) ,Ctr...Controller (control unit), D3...Die (switching processing unit), D5...Die (outer shape cutting unit), G...Through hole (through hole for blank punching), J...Through hole (through hole for detection), M...Defect area, MS...Strip metal plate (strip member), P3...Punch (switching processing unit), P5...Punch (outer shape cutting unit), R1...Removal area, R2...Outer shape cutting area, SE1...Detection unit (another detection unit), SE2...Detection unit, SE3...Detection unit (yet another detection unit), W...Punched member (processed product).

Claims

1. A first step in which a defect in a strip-shaped member, which is sent out in a predetermined one direction by a sending device, is detected by a detection unit before it reaches the press working device, If the defect is detected by the detection unit, a second step is to remove a predetermined removal area from the strip-shaped member, which includes at least a portion of the defect and the outer shape punching area to be punched out by the outer shape punching unit of the press working apparatus, by cutting the area with laser light emitted from the irradiation unit of a laser device located upstream of the press working apparatus in the feeding direction of the strip-shaped member, thereby forming a through hole for blank punching in the removal area of ​​the strip-shaped member. The third step includes punching out the outer shape cutting area of ​​the strip-shaped member in which the removal area has not been formed using the outer shape cutting part to form a processed product, A method for manufacturing a processed product, wherein the size of the removal area is set to be larger than the size of the outer shape removal area.

2. A fourth step involves detecting the position of the through-hole for dry firing formed in the strip-shaped member in the discharge direction using another detection unit, A fifth step is to calculate the amount of displacement of the dry-firing through-hole in the delivery direction based on the position detected by the other detection unit, A sixth step of determining whether the amount of displacement of the through-hole for dry firing is within a predetermined allowable range, The method according to claim 1, further comprising a seventh step of continuing the processing of the strip-shaped member by the press working apparatus when the amount of displacement of the through-hole for dry firing is within the allowable range.

3. The method according to claim 2, further comprising an eighth step of correcting the irradiation position of the laser beam from the irradiation unit in the delivery direction according to the amount of displacement of the through-hole for dry firing when the amount of displacement of the through-hole for dry firing is outside the allowable range.

4. The method according to claim 2, wherein the other detection unit is provided in the laser device so as to be located downstream of the irradiation unit in the delivery direction, or is provided on the upstream end face in the delivery direction of the lower die of the press working device.

5. The method according to claim 2, wherein the other detection unit is configured to detect a detection through-hole provided in the strip-shaped member.

6. The method according to claim 5, wherein the detection through-hole is either the through-hole for dry firing or a through-hole formed separately from the through-hole for dry firing in the strip-shaped member.

7. A ninth step involves detecting the position of the lower die of the press working apparatus in the feeding direction using another detection unit, A tenth step in which the amount of displacement of the outer shape cutout in the feeding direction is calculated based on the position detected by the further detection unit, A 11th step of determining whether the amount of misalignment of the outer shape cutout is within a predetermined separate allowable range, The method according to claim 1, further comprising a twelfth step of correcting the irradiation position of the laser beam from the irradiation unit in the delivery direction according to the amount of misalignment of the outer shape cutout when the amount of misalignment of the outer shape cutout is outside the other allowable range.

8. The method according to claim 7, wherein steps 9 to 12 are performed after the replacement of the lower mold or after the detection unit detects the defective part.

9. The method according to claim 1, wherein the shape of the removal region is a shape that follows the shape of the outer shape removal region.

10. The process further includes a thirteenth step of stacking the processed products formed in the third step in the outer shape cutout section to form a laminate, while counting the number of stacked processed products in the outer shape cutout section. The method according to any one of claims 1 to 9, wherein the 13th step is to not count the number of stacked processed products when the blank-punching through hole reaches the outer shape punching section and the outer shape punching section performs the punching operation of the strip-shaped member.

11. A 14th step involves using a switching processing unit provided in the press working apparatus to selectively form either a crimp or a through hole in the outer shape cutout area of ​​the strip-shaped member where the removal area has not been formed, The process further includes a 15th step of stacking the processed products formed in the third step at the outer shape cutout to form a laminate, The method according to any one of claims 1 to 9, wherein the 14th step includes, when the blank-firing through-hole reaches the switching processing section and it is selected to form the through-hole in the outer shape cutting region, selecting again to form the through-hole in the outer shape cutting region after the blank-firing through-hole has passed through.

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