Laminated core manufacturing apparatus, laminated core manufacturing method, and rotating electric machine manufacturing method

Abstract

Provided is a laminated core production device that can prevent deformation of a laminated core that is cut out of a thin-plate core group.　A laminated core production device (1) cuts a laminated core (32) out of a thin-plate core group (31) of laminated thin-plate cores (31a). The laminated core production device comprises a stopper (6) that restricts the position of the thin-plate core group in the lamination direction of the thin-plate core group, a fixing guide (4) that restricts the position of the thin-plate core group in a direction orthogonal to the lamination direction, and a cutting-out guide (5) that is provided so as to be separated from the fixing guide in the lamination direction, restricts the position of the thin-plate core group in the direction orthogonal to the lamination direction, and moves in the direction orthogonal to the lamination direction to cut the laminated core out of the thin-plate core group.

Description

[Technical field]

[0001] The present application relates to a laminated core, a rotating electric machine, a laminated core manufacturing device, a manufacturing method for a laminated core, and a manufacturing method for a rotating electric machine. [Background technology]

[0002] A laminated core in which thin plate cores made of electromagnetic steel sheets are laminated may be used as a stator core and a rotor core of a rotating electric machine. This laminated core is manufactured by cutting out a laminated core group in a predetermined thickness from a laminated thin plate core group. A conventional laminated core manufacturing device has been disclosed that includes a cutting blade that cuts out a laminated core in a direction perpendicular to the lamination direction of the thin plate core group, a receiving blade that is arranged on the opposite side of the cutting blade across the thin plate core group, and an adjustment device that adjusts the position of the thin plate core group in the lamination direction before cutting out so that the cut out laminated core has a predetermined thickness (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2004-55726 A Summary of the Invention [Problem to be solved by the invention]

[0004] In conventional laminated core manufacturing apparatus, the thin plate core group is simply placed on a transport rail, and therefore there is a problem that the thin plate cores are displaced due to the impact when cut out, resulting in deformation of the laminated core.

[0005] The present application has been made to solve the above-mentioned problems, and has an object to provide a laminated core manufacturing apparatus capable of preventing deformation of a laminated core cut out from a group of thin plate cores. [Means for solving the problem]

[0006] The laminated core manufacturing apparatus of the present application is an apparatus for cutting out a laminated core formed by stacking thin plate cores from a thin plate core group in which thin plate cores are stacked, and includes a stopper for regulating the position of the thin plate core group in the stacking direction of the thin plate core group, a fixed guide for regulating the position of the thin plate core group in a direction perpendicular to the stacking direction, and an excision guide that is provided with a gap between the fixed guide and the stacking direction, regulates the position of the thin plate core group in the direction perpendicular to the stacking direction, and moves in the direction perpendicular to the stacking direction to cut out a laminated core from the thin plate core group, and the stopper is positioned at one end of the stacking direction of the thin plate core group. In this state, the thin plate core group is displaced from the stopper in the cutting direction, and the stopper is displaced from the thin plate core group in the opposite direction to the cutting direction. After the stopper comes into contact with the thin plate core group, The thin plate core group and the laminated core overlap when viewed from the lamination direction. The laminated core is cut out from the thin core group by moving the cutting guide to the position indicated by the arrow. The amount of movement of the cutting guide is A direction perpendicular to the stacking direction in the movement of the part where the stopper and one end of the thin plate core group come into contact is greater than the length of , which is smaller than the width in the direction perpendicular to the stacking direction in the movement of the thin plate core group. is doing. Effect of the Invention

[0007] The laminated core manufacturing device of the present application includes a fixed guide that regulates the position of the thin plate core group in a direction perpendicular to the lamination direction, and a cut-out guide that is provided with a gap between the fixed guide and the lamination direction, regulates the position of the thin plate core group in the direction perpendicular to the lamination direction, and moves in the direction perpendicular to the lamination direction to cut out a laminated core from the thin plate core group. In this state, the thin plate core group is displaced from the stopper in the cutting direction, and the stopper is displaced from the thin plate core group in the opposite direction to the cutting direction. After the stopper comes into contact with the thin plate core group, The thin plate core group and the laminated core overlap when viewed from the lamination direction. The laminated core is cut out from the thin core group by moving the cutting guide to the position indicated by the arrow. The amount of movement of the cutting guide is A direction perpendicular to the stacking direction in the movement of the part where the stopper and one end of the thin plate core group come into contact is greater than the length of , which is smaller than the width in the direction perpendicular to the stacking direction in the movement of the thin plate core group. Therefore, it is possible to prevent deformation of the laminated core cut out from the thin plate core group. In addition, when a laminated core is cut out from a group of thin plate cores, the generation of shavings caused by the thin plate on the fixed guide side of the cut and the cutting guide rubbing against each other, and wear on the cutting guide can be reduced. [Brief description of the drawings]

[0008] [Figure 1] 1 is a perspective view of a laminated core manufacturing apparatus according to a first embodiment. [Diagram 2] 1 is a top view of a laminated core manufacturing apparatus according to a first embodiment. [Diagram 3] 1 is a side view of a laminated core manufacturing apparatus according to a first embodiment. [Figure 4] 1 is an enlarged view of a laminated core manufacturing apparatus according to a first embodiment. [Diagram 5] 5A to 5C are diagrams illustrating a cutting process of a laminated core in the first embodiment. [Figure 6] 5A to 5C are diagrams illustrating a laminated core ejection step in the first embodiment. [Figure 7] 1 is a schematic diagram of an apparatus combining the laminated core manufacturing apparatus of the first embodiment with a press apparatus. [Figure 8] 1 is a top view of a laminated core manufacturing apparatus according to a first embodiment. [Figure 9] 1 is a top view of a laminated core manufacturing apparatus according to a first embodiment. [Figure 10] 5 is an explanatory diagram showing the operation of the laminated core manufacturing apparatus of the first embodiment. FIG. [Figure 11] 1 is a cross-sectional view of a rotating electric machine according to a first embodiment. [Figure 12] FIG. 11 is a perspective view of a laminated core manufacturing device according to a second embodiment. [Figure 13] FIG. 11 is a top view of a laminated core manufacturing apparatus according to a second embodiment. [Figure 14] FIG. 11 is a side view of a laminated core manufacturing apparatus according to the second embodiment. [Figure 15] 11 is an enlarged view of a laminated core manufacturing apparatus according to a second embodiment. FIG. [Figure 16] FIG. 11 is a cross-sectional view of a laminated core manufacturing apparatus according to a second embodiment. [Figure 17] 13A to 13C are diagrams showing a laminated core ejection step in the second embodiment. [Figure 18] 10A to 10C are diagrams showing a cutting process of a laminated core in the second embodiment. [Figure 19] 10A to 10C are diagrams showing a cutting process of a laminated core in the second embodiment. [Figure 20] 11 is an explanatory diagram showing a state when a laminated core in embodiment 2 is cut out. FIG. [Figure 21]11 is an enlarged view of a laminated core manufacturing apparatus according to embodiment 3. FIG. [Figure 22] 11 is an enlarged view of a laminated core manufacturing apparatus according to embodiment 3. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, a laminated core manufacturing apparatus according to an embodiment of the present invention will be described in detail with reference to the drawings. In addition, the same reference numerals in each drawing indicate the same or corresponding parts.

[0010] Embodiment 1 FIG. 1 is a perspective view of a laminated core manufacturing apparatus according to the first embodiment. As shown in FIG. 1, the laminated core manufacturing apparatus 1 of the present embodiment is composed of a base 2 and an extrusion unit 3. The laminated core manufacturing apparatus 1 of the present embodiment has a function of extruding a laminated core 32 of a determined length from an input thin plate core group 31. The thin plate core group 31 is formed by stacking thin plate cores 31a made of electromagnetic steel sheets using a press device. The extrusion unit 3 can move on the base 2 along the stacking direction of the input thin plate core group 31. The extrusion unit 3 is composed of a fixed guide 4, an extrusion guide 5, a stopper 6, and an ejection block 7. Here, in FIG. 1, the stacking direction of the thin plate core group 31 in a state where it is input into the laminated core manufacturing apparatus 1 is the x-axis direction, the direction parallel to the surface of the base 2 perpendicular to the x-axis is the y-axis direction, and the direction perpendicular to the x-axis and y-axis is the z-axis direction.

[0011] FIG. 2 is a top view of the laminated core manufacturing apparatus 1 of this embodiment as viewed from the z-axis direction. FIG. 3 is a side view of the laminated core manufacturing apparatus 1 of this embodiment as viewed from the x-axis direction. As shown in FIG. 3, the fixed guide 4 and the cutting guide 5 are formed with a groove 5a in which a part of the periphery of the thin plate core 31a is embedded along the x-axis direction. Therefore, the position of the thin plate core group 31 put into the laminated core manufacturing apparatus 1 in the y-axis direction is restricted by the groove 5a formed in the fixed guide 4 and the cutting guide 5. This groove 5a has a shape slightly larger than the outer shape of the thin plate core 31a, and when the thin plate core group 31 is inserted into the groove 5a of the fixed guide 4 and the cutting guide 5, a gap is generated between the side wall of the groove 5a and the thin plate core group 31. As shown in FIG. 2, the fixed guide 4 and the cutting guide 5 are arranged with a gap in the x-axis direction. This gap is set to be equal to or smaller than the thickness of the thin plate core 31a. The fixed guide 4 is restricted from moving in the y-axis direction. The cutting guide 5 can move in the y-axis direction. The stopper 6 is disposed so as to come into contact with a part of the tip of the thin core group 31. As shown in Fig. 3, the stopper 6 is disposed at a position that does not interfere with the movement of the cutting guide 5 in the y-axis direction. The ejection block 7 is movable in the x-axis direction.

[0012] Next, the operation of the laminated core manufacturing apparatus 1 of this embodiment will be described. As shown in Figures 1 and 2, the thin plate core group 31 is fed into the laminated core manufacturing apparatus 1 along the x-axis direction. The thin plate core group 31 is inserted until the tip of the thin plate core group 31 contacts the stopper 6 while being fitted into the grooves 5a of the fixed guide 4 and the cutting guide 5. A load is applied to the thin plate core group 31 toward the stopper 6 by a load application unit (not shown).

[0013] FIG. 4 is an enlarged view showing a gap separating the fixed guide 4 and the cutting guide 5 of the laminated core manufacturing apparatus 1 of this embodiment. As shown in FIG. 4, the gap separating the fixed guide 4 and the cutting guide 5 is set to be equal to or smaller than the thickness of the thin plate core 31a. Assume that the slit 31b of the thin plate core group 31 exists between the gap. FIG. 5 is a diagram showing the cutting process of the laminated core in the laminated core manufacturing apparatus 1 of this embodiment. As shown in FIG. 5, the cutting guide 5 moves in the y-axis direction to cut out the laminated core 32 from the thin plate core group 31. At this time, as shown in FIG. 4, the movement of the thin plate core 31c on the fixed guide 4 side of the slit 31b of the thin plate core group 31 in the y-axis direction is restricted by the fixed guide 4. On the other hand, the thin plate core 31d on the cutting guide 5 side of the slit 31b of the thin plate core group 31 moves in the y-axis direction together with the cutting guide 5. In this way, the laminated core 32 is cut out from the thin plate core group 31 with the slit 31b as a boundary.

[0014] Depending on the loading state of the thin plate core group 31, there may be cases where the slit 31b of the thin plate core group 31 does not exist in the gap separating the fixed guide 4 and the cut-out guide 5. In this case, it becomes difficult for the cut-out guide 5 to move in the y-axis direction. In such a case, the load required to move the cut-out guide 5 in the y-axis direction is measured, and if the load exceeds a certain value, the cut-out operation is interrupted. Then, the load of the load application part is adjusted and the cut-out operation is performed again. By repeating this operation, the cut-out operation can be performed reliably.

[0015] 6 is a diagram showing a laminated core discharging process in the laminated core manufacturing apparatus 1 of this embodiment. As shown in FIG. 6, the extrusion guide 5 moves in the y-axis direction to extrude the laminated core 32, and the ejection block 7 moves in the x-axis direction with respect to the extrusion guide 5 moving in the y-axis direction, whereby the laminated core 32 can be ejected from the laminated core manufacturing apparatus 1.

[0016] The laminated core manufacturing apparatus 1 configured as above provides the following five advantages. The first effect is that it is possible to prevent deformation of the laminated core cut out from the thin core group in the cutting and ejecting steps of the laminated core. Since the groove 5a is formed in the fixed guide 4 and the cutting guide 5 along the x-axis direction such that a part of the periphery of the thin core 31a is embedded, the positions of the thin core group 31 and the laminated core 32 in the y-axis direction are always regulated. Therefore, it is possible to prevent deformation of the laminated core 32 cut out from the thin core group 31 in the cutting and ejecting steps of the laminated core. Furthermore, it is not necessary to perform a process of aligning the shape of the laminated core after cutting out the laminated core, which improves productivity.

[0017] The second effect is that the core space factor of the thin core group is improved and warping of the thin cores can be suppressed. Since the load application part applies a load to the thin core group 31 toward the stopper 6, the core space factor of the thin core group 31 is improved and warping of the thin cores 31a can be suppressed.

[0018] The third effect is that the productivity of the cutting-out process of the laminated core is improved. Since the stopper 6 is disposed in a position that does not interfere with the movement of the cutting-out guide 5 in the y-axis direction, the stopper 6 does not interfere with the cutting-out process of the laminated core. Therefore, the process of retracting the stopper 6 is not required, and the productivity is improved.

[0019] The fourth effect is that the equipment cost for the cutting-out process of the laminated core can be reduced. When the thin plate core group 31 is inserted into the cutting-out guide 5, a gap is formed between the side wall of the groove 5a and the thin plate core group 31, so an impact load is applied to the thin plate core group 31 during the cutting-out process of the laminated core. Therefore, the load required to move the cutting-out guide 5 in the y-axis direction during the cutting-out process is small, which reduces the equipment cost.

[0020] The fifth effect is that the generation of shavings caused by friction between the thin plate core and the cutting guide and wear of the cutting guide can be reduced during the cutting process of the laminated core. Since the stopper 6 is arranged so that a part of the tip of the thin plate core group 31 contacts the stopper 6, the movement amount of the cutting guide 5 in the y-axis direction during the cutting process can be reduced. That is, the laminated core can be cut out simply by making the movement amount of the cutting guide 5 in the y-axis direction larger than the length in the y-axis direction where the stopper 6 contacts the thin plate core group 31. Therefore, if the length in the y-axis direction where the stopper 6 contacts the thin plate core group 31 is made as short as possible, the movement amount of the cutting guide 5 in the y-axis direction during the cutting process can be reduced. As a result, when the laminated core 32 is cut out from the thin plate core group 31, the generation of shavings caused by friction between the thin plate core 31c on the fixed guide 4 side of the slit 31b and the cutting guide 5 and wear of the cutting guide 5 can be reduced.

[0021] In the laminated core manufacturing device of this embodiment, the base 2 is located vertically below the extrusion unit 3. The groove 5a shown in Fig. 3 may be shaped to enclose the core back portion of the thin plate core group 31 so that the thin plate core group 31 does not slip out in the z-axis direction. With this configuration, the extrusion unit 3 can operate even when the base 2 is located vertically above it.

[0022] Fig. 7 is a schematic diagram of an apparatus combining the laminated core manufacturing apparatus of this embodiment with a press apparatus for a thin plate core group. As shown in Fig. 7, the lamination direction of the thin plate core group is parallel to the direction of gravity, and the laminated core manufacturing apparatus 1 is disposed vertically below the press apparatus 8 for the thin plate core group. The laminated core 32 cut out by the cutting guide 5 is discharged vertically downward by the force of gravity, so there is no need for a discharge block 7. In addition, the thin plate core group 31 is directly fed from the press apparatus 8 for the thin plate core group into the laminated core manufacturing apparatus 1, which simplifies the manufacturing process.

[0023] 8 and 9 are top views of another laminated core manufacturing apparatus of this embodiment. In the laminated core manufacturing apparatus of this embodiment, the length of the cutting guide 5 in the x-axis direction is set to be larger than the maximum thickness of the laminated core 32. The thickness of the laminated core cut out by this laminated core manufacturing apparatus is determined by the relative positions of the cutting guide 5 and the stopper 6 in the x-axis direction. In the laminated core manufacturing apparatus shown in FIG. 8, the thickness of the laminated core 32 is adjusted using stoppers 6 having different lengths in the x-axis direction. In the laminated core manufacturing apparatus shown in FIG. 9, the thickness of the laminated core 32 is adjusted by moving the positions of the stoppers 6 having the same length in the x-axis direction. In this way, in the laminated core manufacturing apparatus of this embodiment, the thickness of the laminated core can be adjusted by changing to stoppers of different lengths or by moving the positions of stoppers of the same length, thereby improving productivity.

[0024] In the laminated core manufacturing apparatus of this embodiment, the cutting unit 3 can move along the lamination direction, i.e., the x-axis direction, of the thin plate core group 31. By correlating the movement speed of the cutting unit 3 in the x-axis direction with the feeding speed in the x-axis direction of the thin plate core group 31 fed into the laminated core manufacturing apparatus, laminated cores can be continuously cut out from the thin plate core group.

[0025] FIG. 10 is an explanatory diagram showing the operation of continuously cutting out a laminated core from a thin plate core group in the laminated core manufacturing apparatus of this embodiment. As shown in FIG. 10(a), the thin plate core group 31 is inserted into the laminated core manufacturing apparatus 1 from the left side along the x-axis direction. The leading end of the thin plate core group 31 comes into contact with the stopper 6 to start cutting out the laminated core. Next, as shown in FIG. 10(b), the cutting guide 5 moves upward along the y-axis direction to cut out the laminated core 32, and the discharge block 7 moves rightward along the x-axis direction to discharge the laminated core 32. During this cutting and discharging, the cutting unit 3 moves rightward along the x-axis direction on the base 2 at the same speed as the insertion speed of the thin plate core group 31 in the x-axis direction. Next, as shown in FIG. 10(c), the cutting guide 5 and the discharge block 7 return to their initial positions. While the cutting guide 5 and the discharge block 7 return to their initial positions, the cutting unit 3 also moves rightward along the x-axis direction at the same speed as the insertion speed of the thin plate core group 31 in the x-axis direction. Finally, as shown in Fig. 10(d), the cutting unit 3 moves leftward along the x-axis direction on the base 2 and returns to its initial position. Then, as shown in Fig. 10(a), the thin plate core group 31 is inserted into the laminated core manufacturing apparatus 1 from the left side along the x-axis direction. In this way, the laminated core manufacturing apparatus of this embodiment can cut out laminated cores continuously from the thin plate core group by repeating the operations shown in Fig. 10(a) to (d).

[0026] In this embodiment, if the slit 31b of the thin core group 31 does not exist in the gap separating the fixed guide 4 and the extrusion guide 5, and if the load for moving the extrusion guide 5 in the y-axis direction exceeds a certain value, the extrusion operation is interrupted, the load of the load application unit is adjusted, and the extrusion operation is performed again. Instead of this method, the position information of the slit 31b of the thin core group 31 may be read by an image sensor or the like, and the position of the stopper 6 may be adjusted so that the slit 31b is reliably located in the gap separating the fixed guide 4 and the extrusion guide 5. With this configuration, there is no need to interrupt the extrusion operation, and productivity is improved.

[0027] 11 is a cross-sectional view of a rotating electric machine using a laminated core manufactured by the laminated core manufacturing apparatus of this embodiment. This rotating electric machine 21 is composed of a rotor 22 which is a rotating part, a stator 23 which generates a force to rotate the rotor 22, and a frame 24 which fixes the stator 23 and rotatably supports the rotor 22. The stator 23 is composed of a laminated core 32 and a coil 33 which is wound around the laminated core 32 via an insulating material.

[0028] Embodiment 2 In some cases, an adhesive is applied to the side of the thin plate core group so that the laminated thin plate cores do not separate. The laminated core manufacturing device of the second embodiment cuts out a laminated core from a thin plate core group having an adhesive layer made of an adhesive on its side.

[0029] FIG. 12 is a perspective view of a laminated core manufacturing apparatus according to this embodiment. As shown in FIG. 12, the laminated core manufacturing apparatus 1 of this embodiment is composed of a base 2 and a cut-out unit 3. An adhesive layer 31e is formed on the side of the thin plate core group 31. The cut-out unit 3 can move on the base 2 along the stacking direction of the inserted thin plate core group 31. The cut-out unit 3 is composed of a fixed guide 4, a cut-out guide 5, a stopper 6, a cut-out blade 9, and a receiving blade 10. The configurations of the fixed guide 4, the cut-out guide 5, and the stopper 6 are the same as those of the fixed guide, the cut-out guide, and the stopper in the first embodiment. The x-axis, the y-axis, and the z-axis in this embodiment are the same as those in the first embodiment.

[0030] Fig. 13 is a top view of the laminated core manufacturing apparatus 1 of this embodiment as viewed from the z-axis direction. Fig. 14 is a side view of the laminated core manufacturing apparatus 1 of this embodiment as viewed from the x-axis direction. Fig. 15 is an enlarged view of a portion separating the cutting blade 9 and the receiving blade 10 of the laminated core manufacturing apparatus 1 of this embodiment. Fig. 16 is a cross-sectional view taken along line AA in Fig. 13.

[0031] The cutting blade 9 can move in the y-axis direction. The movement of the receiving blade 10 in the y-axis direction is restricted. As shown in FIG. 15, the distance between the cutting blade 9 and the receiving blade 10 in the x-axis direction is set to be greater than or equal to the thickness of the thin core. When the cutting blade 9 moves in the y-axis direction, it comes into contact with the thin core 31d of the thin core group 31. The receiving blade 10 acts to prevent the thin core 31c located on the input side of the thin core 31d with which the cutting blade 9 comes into contact from moving in the y-axis direction. Similarly to the ejection block shown in the first embodiment, the receiving blade 10 can eject the laminated core 32 from the laminated core manufacturing apparatus 1 by moving in the x-axis direction. As shown in FIG. 15, the distance between the fixed guide 4 and the cutting guide 5 in the x-axis direction is set to be greater than the distance between the cutting blade 9 and the receiving blade 10 in the x-axis direction.

[0032] As shown in Fig. 16, the cutting blade 9 has a protrusion 9a that protrudes toward a hole 5b formed in the cutting guide 5. The hole 5b formed in the cutting guide 5 has a structure that has a width in the y-axis direction larger than the protrusion 9a of the cutting blade 9. In Fig. 16, when the cutting blade 9 moves rightward along the y-axis direction, the protrusion 9a comes into contact with the side surface of the hole 5b. Therefore, the cutting guide 5 can move in the y-axis direction in conjunction with the movement of the cutting blade 9 in the y-axis direction.

[0033] Next, the operation of the laminated core manufacturing apparatus 1 of this embodiment will be described. As in the first embodiment, the thin plate core group 31 is fed into the laminated core manufacturing apparatus 1 along the x-axis direction. The thin plate core group 31 is inserted until the tip of the thin plate core group 31 contacts the stopper 6 while being fitted into the groove 5a of the fixed guide 4 and the cutting guide 5.

[0034] Next, the cutting blade 9 moves in the y-axis direction to cut out the laminated core 32 from the thin plate core group 31. At this time, as shown in FIG. 16, the width of the hole 5b of the cutting guide 5 in the y-axis direction is larger than the width of the protrusion 9a of the cutting blade 9, so the cutting blade 9 first comes into contact with the thin plate core group 31. Then, the protrusion 9a of the cutting blade 9 comes into contact with the side of the hole 5b of the cutting guide 5, and the cutting blade 9 and the cutting guide 5 move in the y-axis direction in conjunction with each other. The thin plate core group 31 that the cutting blade 9 comes into contact with tries to move in the y-axis direction, but the thin plate core group 31 on the input side of the cutting blade 9 comes into contact with the receiving blade 10, whose movement in the y-axis direction is restricted. In this way, a shear force can be applied to the thin plate core group 31 by the load applied between the cutting blade 9 and the receiving blade 10.

[0035] Fig. 17 is a diagram showing the discharge step of the laminated core in the laminated core manufacturing apparatus 1 of this embodiment. As shown in Fig. 17, the cut-out blade 9 and the cut-out guide 5 move in the y-axis direction to cut out the laminated core 32, and the receiving blade 10 moves in the x-axis direction, thereby discharging the laminated core 32 from the laminated core manufacturing apparatus 1. In this way, the laminated core manufacturing apparatus of this embodiment can reliably cut out a laminated core from a group of thin plate cores having adhesive layers formed on their side surfaces.

[0036] In the laminated core manufacturing apparatus 1 configured in this manner, the five effects described in the first embodiment can be obtained.

[0037] In addition, in this embodiment, the gap between the fixed guide 4 and the cutting guide 5 in the y-axis direction is set to be equal to or larger than the thickness of the thin core, so that the slits of the thin core group 31 are certainly present in this gap. Therefore, the thin core is not caught in the gap between the fixed guide 4 and the cutting guide 5. Furthermore, the gap between the cutting blade 9 and the receiving blade 10 in the y-axis direction is also set to be equal to or larger than the thickness of the thin core, so there is no problem that the cutting blade 9 and the receiving blade 10 come into contact with the same thin core during cutting. Therefore, there is no need to adjust the position of the slit as described in the first embodiment, and there are advantages in that the equipment cost is reduced and the productivity is improved by reducing the takt time.

[0038] In the laminated core manufacturing apparatus of this embodiment, there may be two or more slits 31b in the thin plate core group 31 between the cutting blade 9 and the receiving blade 10. FIG. 18 is an explanatory diagram of the cutting process in the laminated core manufacturing apparatus of this embodiment when no adhesive layer is formed on the side surface of the thin plate core group 31. When no adhesive layer is formed on the side surface of the thin plate core group 31, the thin plate core 31f between the thin plate core 31d contacted by the cutting blade 9 and the thin plate core 31c contacted by the receiving blade 10 may be displaced or fall off from the thin plate core group 31. This is because the movement of this thin plate core 31f in the y-axis direction is not restricted by the receiving blade 10 or the fixed guide 4.

[0039] FIG. 19 is an explanatory diagram of the cutting process in the laminated core manufacturing apparatus of the present embodiment when an adhesive layer is formed on the side of the thin plate core group 31. As shown in FIG. 19, for example, if the adhesive layer 31e is sheared first at the cut between the thin plate core 31f and the thin plate core 31d, the load applied to the cutting blade 9 becomes smaller. Therefore, the adhesive layer 31e at the cut between the thin plate core 31f and the thin plate core 31c is not sheared until the cutting is completed. As a result, even if the movement in the y-axis direction is not restricted by the receiving blade 10 or the fixed guide 4, the thin plate core 31f is fixed by the adhesive layer 31e, so that the thin plate core 31f does not shift or fall off from the thin plate core group 31. This is the same even if the thin plate core group 31 has three or more cuts. Therefore, even if there are two or more cuts 31b of the thin plate core group 31 between the cutting blade 9 and the receiving blade 10, the cutting can be completed without any problem.

[0040] In this embodiment, it is preferable that the cutting blade 9 and the receiving blade 10 contact the adhesive layer 31e formed on the side of the thin core group 31. If the cutting blade 9 and the receiving blade 10 do not contact the adhesive layer 31e, the adhesive layer may stretch before the adhesive layer is sheared, and the fixing force between the thin cores may decrease. By having the cutting blade 9 and the receiving blade 10 contact the adhesive layer 31e, the extension of the adhesive layer in the portion not in contact with the cutting blade 9 and the receiving blade 10 can be suppressed. In addition, since the width of the hole 5b of the cutting guide 5 in the y-axis direction is larger than the width of the protrusion 9a of the cutting blade 9, an impact load is applied to the thin core group 31 in the cutting process of the laminated core. Therefore, the load required to move the cutting blade 9 in the y-axis direction in the cutting process is small, which saves on equipment costs.

[0041] In this embodiment, the thin plate core group has an adhesive layer formed on the side surface to fix the thin plate core. As another configuration, the thin plate core may be fixed by providing an adhesive layer between the laminations of the thin plate cores constituting the thin plate core group. However, in the conventional laminated core manufacturing device, the thickness of the laminated core formed by this inter-laminar adhesion was determined by the number of laminations of the thin plate core. Therefore, there was a problem that the thickness of the laminated core was not stable due to the variation in the thickness of the thin plate core and the thickness of the adhesive layer. In the laminated core manufacturing device of this embodiment, the thickness of the laminated core is determined by the relative position in the x-axis direction between the cutting guide and the stopper, not the number of laminations of the thin plate core, so that the thickness of the laminated core can be stabilized without being affected by the thickness of the thin plate core and the thickness of the adhesive layer.

[0042] FIG. 20 is an explanatory diagram showing a state when a laminated core is cut out from a thin plate core group in which an adhesive layer is provided between laminations of thin plate cores in the laminated core manufacturing apparatus of this embodiment. FIG. 20 shows a state in which an adhesive layer 41 remains on an end face 42 of the laminated core 32 when the laminated core 32 is cut out from the thin plate core group 31. In FIG. 20, the thickness of the adhesive layer 41 is exaggerated. The actual thickness of the adhesive layer 41 is sufficiently smaller than the thickness of the thin plate core 31a. In this way, the adhesive layer 41 remains on at least one of the end face 42 of the cut laminated core 32 and the end face 43 of the thin plate core group 31 after the laminated core 32 is cut out.

[0043] Also, the thin cores constituting the thin core group may be fixed by caulking. However, in conventional laminated core manufacturing devices, the thickness of the laminated cores fixed by caulking is determined by the number of laminated thin cores. Therefore, even with this laminated core, there is a problem that the thickness of the laminated core is not stable due to the variation in the thickness of the thin cores. In the laminated core manufacturing device of this embodiment, the thickness of the laminated core is determined by the relative position of the cutting guide and the stopper in the x-axis direction, not the number of laminated thin cores, so that the thickness of the laminated core can be stabilized without being affected by the thickness of the thin cores.

[0044] Embodiment 3 The thin plate core group may be stacked in a state where the thin plate cores are tilted from a direction perpendicular to the stacking direction due to the influence of the variation in plate thickness of the thin plate cores and the precision of the device that stacks the thin plate cores to manufacture the thin plate core group. The laminated core manufacturing device of the third embodiment is capable of cutting out a laminated core from a thin plate core group in which the thin plate cores are stacked in a tilted state. The configuration of the laminated core manufacturing device of the present embodiment is the same as that of the laminated core manufacturing device of the first embodiment. However, the gap in the x-axis direction between the fixed guide and the cutting guide is set to a predetermined range.

[0045] In the laminated core manufacturing apparatus of the first embodiment, if the gap between the fixed guide 4 and the cutting guide 5 in the x-axis direction exceeds the thickness of the thin plate core, the thickness of the cut laminated core may vary. For example, referring to FIG. 4 of the first embodiment, if the gap between the fixed guide 4 and the cutting guide 5 in the x-axis direction exceeds the thickness of the thin plate core, there may be two slits 31b in the thin plate core group 31 between the gap separating the fixed guide 4 and the cutting guide 5. In this case, the laminated core will be cut out from the thin plate core group at one of the two slits 31b, and the thickness of the cut laminated core will vary by the thickness of one thin plate core. In order to prevent such variation in the thickness of the laminated core, in the laminated core manufacturing apparatus of the first embodiment, the gap between the fixed guide 4 and the cutting guide 5 in the x-axis direction is set to be equal to or smaller than the thickness of the thin plate core 31a.

[0046] In contrast, in the laminated core manufacturing apparatus of this embodiment, the gap 44 in the x-axis direction between the fixed guide 4 and the cut-out guide 5 is set to be equal to or larger than half the thickness of the thin plate core 31a and equal to or smaller than the thickness of the thin plate core 31a. FIG. 21 is an enlarged view showing a portion separating the fixed guide 4 and the cut-out guide 5 of the laminated core manufacturing apparatus of this embodiment. If the distance of the gap in the x-axis direction between the fixed guide 4 and the cut-out guide 5 is reduced, it may be difficult for the cut-out guide 5 to move in the y-axis direction when a group of thin plate cores in a tilted state are loaded into the laminated core manufacturing apparatus. For example, in the case where the thin plate cores are in a tilted state as shown in FIG. 21, the thin plate core 31g in the gap separating the fixed guide 4 and the cut-out guide 5 may have one end in the y-axis direction restricted by the fixed guide 4 and the other end in the y-axis direction restricted by the cut-out guide 5. If a thin plate core 31g in such a state exists, it is difficult for the cut-out guide 5 to move in the y-axis direction. In this case, as described in the first embodiment, the load required to move the cutting guide 5 in the y-axis direction is measured, and if the load exceeds a certain value, the cutting operation is interrupted. Then, the load of the load application unit is adjusted and the cutting operation is performed again.

[0047] Fig. 22 is an enlarged view showing a portion separating the fixed guide 4 and the extrusion guide 5 when the load of the load application unit is adjusted. As shown in Fig. 22, by repeating this operation until one end of the thin core 31g in the y-axis direction is no longer restricted by the fixed guide 4, the extrusion operation can be performed reliably.

[0048] To reliably execute the cutting operation with such repeated operations, in the laminated core manufacturing apparatus of this embodiment, the gap 44 in the x-axis direction between the fixed guide 4 and the cutting guide 5 is set to be equal to or more than half the thickness of the thin plate core 31a and equal to or less than the thickness of the thin plate core 31a. In the laminated core manufacturing apparatus configured in this manner, even if a group of thin plate cores stacked with the thin plate cores tilted is input, the laminated cores can be cut out reliably without variation in thickness.

[0049] Although the present application describes various exemplary embodiments, the various features, aspects, and functions described in one or more embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless modifications not exemplified are assumed within the scope of the technology disclosed in this application, including, for example, modifying, adding, or omitting at least one component, and further, extracting at least one component and combining it with a component of another embodiment. [Explanation of symbols]

[0050] 1 laminated core manufacturing device, 2 base, 3 cutting unit, 4 fixed guide, 5 cutting guide, 5a groove, 5b hole, 6 stopper, 7 discharge block, 8 press device, 9 cutting blade, 9a protrusion, 10 receiving blade, 21 rotating electric machine, 22 rotor, 23 stator, 24 frame, 31 thin plate core group, 31a, 31c, 31d, 31f, 31g thin plate core, 31b cut, 31e adhesive layer, 32 laminated core, 33 coil, 41 adhesive layer, 42, 43 end surface, 44 gap.

Claims

1. A laminated core manufacturing apparatus for cutting out a laminated core formed by stacking thin plate cores from a thin plate core group in which the thin plate cores are stacked, comprising: a stopper that regulates a position of the thin plate core group in a stacking direction of the thin plate core group; a fixed guide that regulates the position of the thin plate core group in a direction perpendicular to the stacking direction; an extrusion guide provided in the stacking direction with a gap between the fixed guide and the thin plate core group, the extrusion guide restricting a position of the thin plate core group in a direction perpendicular to the stacking direction and moving in the direction perpendicular to the stacking direction to extrude the laminated core from the thin plate core group, a laminated core manufacturing device for cutting out a laminated core from a thin plate core group by moving the excision guide until the stopper and the thin plate core group are no longer in contact with each other and the thin plate core group and the laminated core overlap when viewed from the stacking direction, and the laminated core is cut out from the thin plate core group while the stopper is shifted in the direction opposite to the excision direction at one end of the thin plate core group in the stacking direction, and the laminated core is cut out from the thin plate core group by moving the excision guide until the stopper and the thin plate core group are no longer in contact with each other and the thin plate core group and the laminated core overlap when viewed from the stacking direction, and the amount of movement of the excision guide is greater than the length of the portion where the stopper and the portion of the one end of the thin plate core group come into contact in a direction perpendicular to the stacking direction and is smaller than the width of the thin plate core group in the direction perpendicular to the stacking direction.

2. 2. The laminated core manufacturing device according to claim 1, wherein the stopper is fixed so as to prevent movement in a direction perpendicular to the lamination direction.

3. 3. The laminated core manufacturing apparatus according to claim 1, wherein the gap is set to be equal to or larger than half the thickness of the thin plate core and equal to or smaller than the thickness of the thin plate core.

4. 4. The laminated core manufacturing apparatus according to claim 1, further comprising a load application unit for applying a load to the thin plate core group in the lamination direction.

5. 5. The laminated core manufacturing device according to claim 1, wherein the stopper is movable along the lamination direction.

6. A laminated core manufacturing apparatus as described in any one of claims 1 to 5, characterized in that the cutting guide moves in the stacking direction, and the moving speed of the cutting guide in the stacking direction is the same as the input speed of the thin plate core group in the stacking direction.

7. 7. The laminated core manufacturing apparatus according to claim 6, wherein while the movement of the cutting guide in the direction perpendicular to the stacking direction is being performed, the cutting guide moves in the stacking direction.

8. 8. The laminated core manufacturing apparatus according to claim 1, further comprising a discharge block that discharges the laminated core cut out by the cut-out guide from the cut-out guide along the stacking direction.

9. A laminated core manufacturing apparatus as described in any one of claims 1 to 8, characterized in that the cutting guide has a groove that regulates the position of the thin plate core group, and there is a gap between the side wall of the groove and the thin plate core group whose position is regulated by the groove.

10. The laminated core manufacturing apparatus as described in claim 1 or 2, further comprising a cutting blade that moves in a direction perpendicular to the stacking direction in conjunction with the cutting guide, and a receiving blade that is arranged on the opposite side of the cutting blade across the thin core group and has a gap between the cutting blade and the cutting blade in the stacking direction.

11. 11. The laminated core manufacturing apparatus according to claim 10, wherein the receiving blade ejects the laminated core cut by the cutting guide from the cutting guide along the lamination direction.

12. The laminated core manufacturing apparatus described in claim 10 or 11, characterized in that the thin core group has an adhesive layer on a side surface in the stacking direction and a core back portion connected to the side surface, the cutting blade contacts the adhesive layer, and the cutting guide has a shape that wraps around the core back portion of the thin core group.

13. A method for manufacturing a laminated core, using the laminated core manufacturing apparatus according to claim 1, for cutting out a laminated core formed by stacking thin plate cores from a thin plate core group in which the thin plate cores are stacked, the method comprising the steps of: A method for manufacturing a laminated core, characterized in that a position of the thin plate core group in the stacking direction is restricted using a stopper that contacts one end of the thin plate core group in the stacking direction, and then the excision guide is moved until the stopper and the thin plate core group are no longer in contact, thereby excising the laminated core from the thin plate core group, and the amount of movement of the thin plate core group in a direction perpendicular to the stacking direction is greater than the length in the direction perpendicular to the stacking direction at which the stopper was brought into contact with the thin plate core group before the excision guide moved.

14. A method for producing a rotating electric machine, comprising the steps of: producing the rotating electric machine by using the laminated core produced by the method for producing the laminated core according to claim 13 .

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