Motor core manufacturing method and manufacturing device

Abstract

To provide a manufacturing method of a motor core and a manufacturing device which allow improvement of productivity.SOLUTION: In a pressing step S1, a belt-like magnetic steel plate 17 is sequentially drawn in a metal mold device 3, and veneer 19 with a carrier is processed by press to be discharged. In a lamination step S2, the discharged veneer 19 with the carrier is sequentially drawn in a lamination device 5, a laminated iron core on which an annular iron core piece is positioned and laminated on a replaceably preset alignment jig is formed, the alignment jig on which the laminated iron core is laminated is taken out, the next jig is set, the alignment jig 25 on which the laminated iron core 29 is laminated is taken out and the next alignment jig 25 is set until a position in the vertical direction of the veneer 19 with the carrier reaches a lower limit of a setting range while continuing the pressing step S1 after relatively delaying speed of the pressing step S1 before completion of the lamination step S2 to raise the position in the vertical direction of the veneer 19 with the carrier within the setting range according to a slack amount.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a method and an apparatus for manufacturing a motor core of an electric motor. [Background technology]

[0002] As a conventional method for manufacturing a motor core, for example, Patent Document 1 describes a method for manufacturing a laminated core for a vehicle drive motor.

[0003] This manufacturing method includes a pressing process and a lamination process, which are carried out using an independent die device and lamination assembly device (lamination device).

[0004] In the pressing process, a strip of magnetic steel sheet is pressed in a die device to produce a carrier-attached veneer in which multiple arc-shaped core pieces are connected at connecting parts. This carrier-attached veneer is wound on a reel and sent to the next lamination process.

[0005] In the lamination process, the veneer with the carrier wound on a reel is pulled into a lamination assembly device, and the arc-shaped core pieces are sequentially cut off from the veneer with the carrier. The cut-off arc-shaped core pieces are pushed by a punch onto an alignment jig set in the lamination assembly device.

[0006] When the arc-shaped core pieces are pressed in, the positioning holes of the arc-shaped core pieces are fitted onto the positioning pins of the alignment jig to position them. With this positioning, the arc-shaped core pieces are arranged in a ring shape to form annular core pieces. These ring-shaped core pieces are stacked in order with the phases shifted to form a laminated core. The inner or outer periphery of the laminated core is welded along the stacking direction.

[0007] Such conventional manufacturing methods can reduce manufacturing costs by using inexpensive equipment.

[0008] However, the veneer with the carrier discharged from the die device must be wound on a reel before being transferred to the next lamination process, which places a limit on the improvement of productivity. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Patent No. 6469355 Summary of the Invention [Problem to be solved by the invention]

[0010] The problem to be solved was the limitation in improving the productivity of motor cores. [Means for solving the problem]

[0011] The present invention provides a method for manufacturing a motor core, comprising a press step for forming a veneer with a carrier and a lamination step for forming a laminated iron core, in which in the press step, strip-shaped magnetic steel sheets are successively drawn into a die device and the veneer with a carrier is processed and discharged by a press, and in the lamination step, the discharged veneer with a carrier is successively drawn into a lamination device to form the laminated iron core in which annular core pieces are positioned and laminated on an alignment jig that is set in advance to be replaceable, and the vertical position of the veneer with a carrier is allowed to move up and down within a set range depending on the amount of sagging of the veneer with a carrier due to the difference between the speed of the press step and the speed of the lamination step between the die device and the lamination device, and the speed of the press step is relatively slowed down just before the completion of the lamination step to raise the vertical position within the set range, and then, while continuing the press step, the alignment jig on which the laminated iron core is stacked is removed before the vertical position reaches the lower limit of the set range, and a next alignment jig is set.

[0012] The present invention provides a motor core manufacturing device comprising: a die device which sequentially draws in a strip-shaped magnetic steel plate and uses a press to process and discharge a veneer with a carrier; a lamination device which sequentially draws in the discharged veneer with a carrier and forms a laminated core in which annular core pieces are positioned and stacked on an alignment jig that is set in advance to be replaceable; a detection device which detects, between the die device and the lamination device, that the vertical position of the veneer with a carrier moves up and down within a set range in accordance with the amount of slack of the veneer with a carrier due to the difference between the operating speed of the die device and the operating speed of the lamination device; and a control device which relatively slows down the operating speed of the die device just before the formation of the laminated core is completed to raise the vertical position within the set range, and then, while continuing the operation of the die device, stops the lamination device before the vertical position reaches the lower limit of the set range, removes the alignment jig on which the laminated core is stacked, and enables the next alignment jig to be set. Effect of the Invention

[0013] According to the present invention, the veneer with carrier discharged from the die device can be pulled directly into the lamination device for lamination, improving the productivity of motor cores. Moreover, by utilizing the slack of the veneer with carrier between the die device and the lamination device, the alignment jig on which the laminated cores are stacked can be removed without stopping the die device and the next alignment jig can be set, thereby preventing the die device from being repeatedly driven and stopped, thereby protecting it. [Brief description of the drawings]

[0014] [Figure 1] Fig. 1(A) is a schematic block diagram showing an overview of a motor core manufacturing apparatus according to an embodiment of the present invention, and Fig. 1(B) is a schematic block diagram showing an overview of a motor core manufacturing apparatus according to a comparative example. [Diagram 2] FIG. 2 is a schematic diagram showing a main part of the manufacturing apparatus for the motor core of FIG. [Diagram 3] FIG. 3 is a perspective view of a main part of a lamination step in which the extended arc-shaped core pieces are arranged on an alignment jig according to the embodiment. [Figure 4]FIG. 4 is a perspective view of a laminated core stacked on an alignment jig according to the embodiment. [Diagram 5] FIG. 5 is a table showing a control example according to the embodiment. [Figure 6] FIG. 6 is a table showing a control example according to the modified example. [Figure 7] FIG. 7 is a table showing a control example according to another modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The present invention achieves the object of enabling improvement in the productivity of motor cores while protecting the die device.

[0016] The manufacturing method of the motor core of the present invention includes a press step S1 of the carrier-equipped veneer 19 and a lamination step S2 of forming a laminated core 29. In the press step S1, the strip-shaped magnetic steel sheet 17 is successively drawn into a die device 3, and the carrier-equipped veneer 19 is processed by pressing and discharged. In the lamination step S2, the discharged carrier-equipped veneer 19 is successively drawn into a lamination device 5, and a laminated core 29 is formed in which the annular core pieces 27 are positioned and laminated on an alignment jig 25 that is set in advance and replaceable.

[0017] This manufacturing method allows the vertical position of the veneer with carrier 19 to move up and down within a set range according to the amount of sagging of the veneer with carrier 19 due to the difference between the speed of the pressing step S1 and the lamination step S2 between the die device 3 and the lamination device 5. Then, just before the lamination step S2 is completed, the speed of the pressing step S1 is relatively slowed down to raise the vertical position of the veneer with carrier 19 within the set range, and then, while continuing the pressing step S1, the alignment jig 25 on which the laminated iron cores 29 are stacked is removed and the next alignment jig 25 is set before the vertical position of the veneer with carrier 19 reaches the lower limit of the set range.

[0018] The speed of the press process S1 may be set to a set low press speed value just before the completion of the lamination process S2, and when the amount of slack in the carrier-attached veneer 19 has decreased to a set value, the speed of the lamination process S2 may be set to a low lamination speed value set in accordance with the low press speed value.

[0019] In this case, the speed of the lamination step S2 can be set to a medium lamination speed set in a range faster than the low lamination speed while maintaining the low press speed until the sagging amount of the veneer 19 with carrier is reduced to a set value.

[0020] Furthermore, in this case, the range in which the amount of sagging of the veneer with carrier 19 decreases due to the lamination medium speed value is set as the lamination medium speed range, and the speed of the lamination process S2 can be set to a lamination high speed value set in a range faster than the lamination medium speed value while maintaining the press low speed value until the amount of sagging of the veneer with carrier 19 reaches the lamination medium speed range.

[0021] In another embodiment, the speed of the lamination process S2 may be set to a set lamination high-speed value just before the completion of the lamination process S2, and the speed of the press process S1 may be set to a set press high-speed value when the amount of sagging of the veneer 19 with carrier is reduced to a set value.

[0022] In this case, the speed of the pressing step S1 can be set to a medium pressing speed set in a range slower than the high pressing speed while maintaining the high lamination speed until the amount of slack in the veneer 19 with a carrier is reduced to a set value.

[0023] Furthermore, in this case, the range in which the sagging amount of the veneer 19 with a carrier decreases due to the medium press speed value is set as the medium press speed range, and the speed of the press process S1 can be set to a low press speed value set in a range slower than the medium press speed value while maintaining the high lamination speed value until the sagging amount of the veneer 19 with a carrier reaches the medium press speed range.

[0024] In yet another embodiment, just before the completion of the lamination process S2, the speed of the press process S1 may be set to a set high-speed press value and the speed of the lamination process S2 may be set to a set maximum lamination speed value, and when the sagging amount of the carrier-attached veneer 19 has decreased to a set value, the speed of the lamination process S2 may be set to a high-speed lamination value set in accordance with the high-speed press value while maintaining the high-speed press value.

[0025] The motor core manufacturing apparatus 1 of the present invention comprises a die device 3, a lamination device 5, a detection device 39, and a control device 7. The die device 3 sequentially draws in a strip-shaped magnetic steel sheet 17 and processes and discharges a veneer with a carrier 19 by a press. The lamination device 5 sequentially draws in the discharged veneer with a carrier 19 and forms a laminated core 29 in which the annular core pieces 27 are positioned and laminated on an alignment jig that is set in advance to be replaceable. The detection device 39 detects that the vertical position of the veneer with a carrier 19 moves up and down within a set range depending on the amount of sagging of the veneer with a carrier 19 due to the difference between the operating speed of the die device 3 and the operating speed of the lamination device 5 between the die device 3 and the lamination device 5. Just before the formation of the laminated iron core 29 is completed, the control device 7 relatively slows down the operating speed of the die device 3 to raise the vertical position within a set range, and then, while maintaining the operation of the die device 3, stops the stacking device 5 before the vertical position reaches the lower limit of the set range, removes the alignment jig 25 on which the laminated iron core 29 is stacked, and enables the next alignment jig 25 to be set.

[0026] The detection device 39 may include an upper sensor 45b that detects when the vertical position of the veneer with carrier 19 rises and the amount of sagging decreases to a set value, and lower sensors 45c to 45f that detect when the vertical position of the veneer with carrier 19 falls and the amount of sagging increases above the set value.

[0027] The detector 39 may also include an upper limit sensor 45a for detecting when the vertical position of the veneer board 19 with a carrier is outside the upper limit of a set range, and a lower limit sensor 45g for detecting when the vertical position of the veneer board 19 with a carrier is outside the lower limit of a set range. In this case, the upper sensor 45b and the lower sensors 45c to 45f are located between the upper limit sensor 45a and the lower limit sensor 45g. EXAMPLES

[0028] [Motor core manufacturing equipment] FIG. 1(A) is a schematic block diagram showing an overview of a motor core manufacturing apparatus according to an embodiment of the present invention. FIG. 1(B) is a schematic block diagram showing an overview of a motor core manufacturing apparatus according to a comparative example. FIG. 2 is a schematic diagram showing a main part of the motor core manufacturing apparatus of FIG. 1(A). FIG. 3 is a perspective view of a main part of a lamination process in which extended arc-shaped core pieces are arranged on an alignment jig according to an embodiment. FIG. 4 is a perspective view of a laminated core laminated on an alignment jig according to an embodiment. FIG. 5 is a chart showing a control example according to an embodiment.

[0029] 1(A) and 2, the motor core manufacturing apparatus 1 of this embodiment includes an uncoiler 9, a die device 3, a lamination device 5, a loop controller 7, and a welding device 11. The motor core to be manufactured includes both a stator core and a rotor core.

[0030] The uncoiler 9 sequentially draws the strip-shaped magnetic steel sheet 17 held in a roll into the die device 3. The uncoiler 9 can be realized by a known device.

[0031] The die device 3 executes the pressing step S1, sequentially drawing in the strip-shaped magnetic steel plate 17, and processes and discharges the carrier-equipped veneer plate 19 by pressing. The pressing step S1 will be described later. The discharge port of the die device 3 is provided with a guide 21 that curves downward. The die device 3 can be realized by a known device.

[0032] The die device 3 of this embodiment presses the veneer plate 19 with a carrier in which arc-shaped core pieces 33 are connected by the connecting portions 31. The die device 3 may also form the veneer plate 19 with a carrier in which annular core pieces 27 are connected by the connecting portions 31.

[0033] The lamination device 5 executes the lamination step S2, sequentially drawing in the carrier-attached veneers 19 discharged from the die device 3, and forming a laminated core 29 in which the annular core pieces 27 are positioned and laminated on an alignment jig 25 that is set in advance so as to be replaceable. The lamination device 5 can be realized by a known device.

[0034] The lamination device 5 of this embodiment separates the arc-shaped core pieces 33 from the veneer sheets 19 with carriers, arranges them in a ring shape on the alignment jig 25, and stacks them as annular core pieces 27 to form a laminated core 29. However, in the case of veneer sheets 19 with carriers in which the annular core pieces 27 are connected by connecting portions 31, the lamination device 5 separates the annular core pieces 27 from the veneer sheets 19 with carriers, and stacks them on the alignment jig 25 to form the laminated core 29.

[0035] This lamination device 5 is provided with a guide roller 23 on the drawing-in side. The veneer 19 with a carrier discharged from the die device 3 is wound around the guide roller 23 and drawn in.

[0036] The loop controller 7 constitutes a detection device and a control device, and detects whether the vertical position of the veneer with carrier 19 moves up and down within a set range depending on the amount of sagging of the veneer with carrier 19, as shown in Figure 2, and controls the speed of the pressing process S1 (operation of the die device 3) and the lamination process S2 (operation of the lamination device 5).

[0037] Through this control, the loop controller 7 relatively slows down the speed of the pressing process S1 just before the lamination process S2 is completed (just before the formation of the laminated iron core 29 is completed) so that the vertical position of the carrier-attached veneer 19 rises within a set range and the amount of sagging is reduced.

[0038] Thereafter, while continuing the pressing step S1, the amount of slack in the veneer plate 19 with carrier increases until the vertical position of the veneer plate 19 with carrier reaches the lower limit of the set range, at which point the lamination step S2 is stopped, the alignment jig 25 on which the laminated cores 29 are stacked is removed, and the next alignment jig 25 can be set. The loop controller 7 will be described in more detail later.

[0039] The removal of the alignment jig 25 on which the laminated cores 29 are stacked and the setting of the next alignment jig are automatically performed by a robot arm (not shown). However, it is also possible for an operator to manually remove and set the alignment jig using a transport jig or the like.

[0040] The operation of the die device 3 refers to the operation of sequentially drawing in the strip-shaped magnetic steel plate 17, processing and discharging the carrier-equipped veneer 19 by a press. The operation of the lamination device 5 refers to the operation of sequentially drawing in the carrier-equipped veneer 19 discharged from the die device 3, and forming a laminated core 29 in which the annular core pieces 27 are positioned and laminated on an alignment jig 25 that is set in advance and replaceable.

[0041] The alignment jig 25 on which the laminated cores 29 have been stacked is removed and the next alignment jig is set when the stacking rate of the annular core pieces 27 to the laminated cores 29 reaches 100%. The stacking rate will be described later.

[0042] The welding device 11 is configured to receive and weld the laminated core 29. Note that a plurality of welding devices 11 may be provided. In this case, the laminated core 29 can be distributed and transported from the lamination device 5 to a plurality of welding devices 11, and welding of the plurality of laminated cores 29 can be performed in parallel. The welding device 11 can be realized by a known device.

[0043] In this motor core manufacturing apparatus 1, the veneer with a carrier 19 is not wound on a reel, but the lamination device 5 directly draws in the veneer with a carrier 19 discharged from the die device 3 and forms the laminated core 29.

[0044] 2, the loop controller 7 is installed between the die device 3 and the lamination device 5. The loop controller 7 includes a detection unit 39 of the detection device and a control unit 41 of the control device.

[0045] The detection unit 39 detects that the vertical position of the carrier-attached veneer 19 rises and falls within a set range due to the difference in speed between the press process S1 and the stacking process S2 between the mold device 3 and the stacking device 5, causing the amount of sagging of the carrier-attached veneer 19 to decrease and increase.

[0046] The sagging of the veneer with carrier 19 means that the veneer with carrier 19 is bent downwardly by its own weight between the die device 3 and the lamination device 5. The amount of sagging is set by the magnitude of the convexity caused by this curvature. The vertical position of the veneer with carrier 19 means the vertical position of the part of the veneer with carrier 19 facing the detection unit 39 where sagging occurs, and there is a relationship in which the amount of sagging decreases as the detection unit 39 rises and increases as the detection unit 39 falls. In this embodiment, the vertical position of the veneer with carrier 19 means the vertical position of the part located at the lowest position of the sagging part, but it may be the vertical position of any part of the sagging part. The setting range of the vertical position of the veneer with carrier 19 is determined in consideration of the replacement of the alignment jig 25, production efficiency, etc. in relation to the amount of sagging.

[0047] The detection unit 39 of this embodiment includes first to seventh sensors 45a, 45b, 45c, 45d, 45e, 45f, and 45g as a plurality of sensors on the upper and lower sides of the detection tower 43. The first to seventh sensors 45a, 45b, 45c, 45d, 45e, 45f, and 45g are configured by, for example, optical sensors.

[0048] The vertical interval between the first and second sensors 45a and 45b is a, the vertical interval between the second and third sensors 45b and 45c is b, the vertical interval between the third and fourth sensors 45c and 45d is c, the vertical interval between the fourth and fifth sensors 45d and 45e is d, the vertical interval between the fifth and sixth sensors 45e and 45f is e, and the vertical interval between the sixth and seventh sensors 45f and 45g is f. The size of each interval is set, for example, as follows: <b<c=d> e>f. However, it can also be arranged with equal intervals of a=b=c=d=e=f.

[0049] The second sensor 45b is a higher-level sensor that detects when the vertical position of the veneer board with a carrier 19 rises and the amount of sagging decreases to a set value. The third to sixth sensors 45c to 45f are lower-level sensors that detect when the vertical position of the veneer board with a carrier 19 falls and the amount of sagging increases beyond the set value.

[0050] In this embodiment, the only upper sensor is the second sensor 45b, but it is also possible to provide multiple sensors above and below and selectively use the multiple sensors to change the set value for the amount of slack for setting the next alignment jig 25.

[0051] Although the lower level sensor is a plurality of sensors, namely the third to sixth sensors 45c to 45f, it may be configured with a single sensor, and at least one sensor is sufficient.

[0052] The first sensor 45a detects when the vertical position of the veneer with carrier 19 is outside the upper allowable limit, i.e., when the amount of sagging is outside the lower allowable limit, and the seventh sensor 45g detects when the vertical position of the veneer with carrier 19 is outside the lower allowable limit, i.e., when the amount of sagging is outside the upper allowable limit. The second to sixth sensors 45b to 45f are located between the first sensor 45a and the seventh sensor 45g.

[0053] The control unit 41 receives inputs from the first to seventh sensors 45a, 45b, 45c, 45d, 45e, 45f, and 45g. The control unit 41 executes control to allow the vertical position of the carrier-attached veneer 19 to move up and down within a set range in response to inputs from the second to sixth sensors 45b, 45c, 45d, 45e, and 45f, thereby decreasing and increasing the amount of sagging.

[0054] Allowing the vertical position of the carrier-attached veneer 19 to rise and fall within a set range to decrease and increase the amount of sagging can be achieved by controlling the tension of the carrier-attached veneer 19 to rise and fall within a set range by adjusting the pressing speed of the die device 3 and the stacking speed of the stacking device 5.

[0055] In this control, the control unit 41 executes control based on the detection so that the vertical position of the carrier-attached veneer 19 rises and the amount of sagging decreases to a set value before the lamination step S2 is completed. In this control, the press speed may be relatively slowed down.

[0056] In this embodiment, just before the completion of the lamination process S2 refers to the penultimate several sheets to the tens of sheets when forming the laminated core 29 by laminating the annular core pieces 27. This setting is appropriately set in relation to the speed of the pressing process of the die device 3, the speed of the lamination process of the lamination device 5, and the vertical position (increase or decrease in the amount of sagging) of the veneer plate with carrier 19 detected by the second to sixth sensors 45b, 45c, 45d, 45e, 45f.

[0057] The number of laminated sheets can be detected directly or indirectly by detecting the number of sheets separated from the carrier-attached veneer 19, or indirectly by counting time and indirectly by detecting the length of retraction and the amount of slack of the carrier-attached veneer 19.

[0058] In this way, the loop controller 7 changes the speed of the pressing process and the speed of the stacking process according to the vertical position of the carrier-attached veneer 19 and the number of stacked annular core pieces 27 .

[0059] [Motor core manufacturing method] In the manufacturing method of the motor core of this embodiment, a pressing step S1 and a lamination step S2 are performed.

[0060] As shown in FIG. 2, in the pressing step S1, a strip-shaped magnetic steel sheet 17 supplied from the uncoiler 9 shown in FIG. 1 is drawn into the die device 3 and pressed into the magnetic steel sheet 17 by a punch shot.

[0061] The carrier-attached veneer 19 is processed by this press processing and continuously discharged. The carrier-attached veneer 19 thus discharged hangs down along a guide 21, passes through a loop controller 7, and is guided by a guide roller 23 and is drawn into the lamination device 5.

[0062] In the lamination step S2, the lamination device 5, in which the alignment jig 25 shown in Figures 3 and 4 is set in advance so as to be replaceable, forms a laminated core 29 in which the annular core pieces 27 are positioned and laminated on the alignment jig 25.

[0063] In this lamination step S2, a cut press is performed with a punch on the carrier-attached veneers 19 that are successively drawn into the lamination device 5. This cut press separates the arc-shaped core pieces 33 from the connecting portions 31. The separated arc-shaped core pieces 33 are pressed onto the alignment jig 25 by the punch.

[0064] The alignment jig 25 has guide pins 35 spaced at regular intervals in the circumferential direction. The arc-shaped core piece 33 is positioned by fitting its positioning hole into the guide pin 35. When the pressing of one arc-shaped core piece 33 is completed, the alignment jig 25 is rotated and the next arc-shaped core piece 33 is pressed in by the punch.

[0065] By repeating this process, the arc-shaped core pieces 33 are arranged in a ring shape on the alignment jig 25. In this way, the annular core pieces 27 are formed and positioned on the alignment jig 25. The arc-shaped core pieces 33 are again arranged in a ring shape on the annular core pieces 27 thus positioned, and the annular core pieces 27 are stacked one after another. When the number of stacked annular core pieces 27 reaches a set number, the laminated core 29 is formed.

[0066] When the formation of the laminated core 29 is completed in this manner, the lamination device 5 is stopped, the alignment jig 25 on which the laminated core 29 has been laminated is removed, and the next alignment jig 25 is set. This removal and setting is performed automatically by a robot arm (not shown) provided in the lamination device 5 counting the number of laminated annular core pieces 27.

[0067] During the time between removing the alignment jig 25 on which the laminated iron cores 29 are stacked and setting the next alignment jig, the die device 3 continues to operate and the stacking device 5 is stopped.

[0068] In other words, only the stacking device 5 is stopped to maintain the press, and the alignment jig 25 on which the laminated iron cores 29 are stacked is removed and the next alignment jig 25 is set during the time period during which the vertical position of the carrier-mounted veneer 19 reaches the lower limit of the set range.

[0069] Therefore, the veneer 19 with a carrier discharged from the die device 3 in the pressing step S1 can be directly pulled into the laminating device 5 for the laminating step, thereby improving the productivity of the motor core.

[0070] This eliminates the need for reel replacement in the press process S1 and the lamination process S2, and makes it possible to make the time required for one shot of the punch in the press processing of the die device 3 the same as or similar to the time required for one shot of the punch in the cut press in the lamination process S2, thereby improving production capacity.

[0071] For this purpose, as shown in FIG. 2, the loop controller 7 detects the amount of slack in the veneer 19 with a carrier and controls the die device 3 and the laminating device 5.

[0072] FIG. 5 is a diagram showing an example of control.

[0073] The indications of "first sensor to seventh sensor" in FIG. 5 correspond to the first sensor to seventh sensor 45a, 45b, 45c, 45d, 45e, 45f, and 45g in FIG.

[0074] 5 is used when removing the alignment jig 25 on which the laminated cores 29 are stacked and setting the next alignment jig. This stacking rate is determined by the relationship between the number of annular core pieces 27 already stacked on the alignment jig 25 and the set number of laminated cores 29, as follows:

[0075] Lamination rate = number of layers already laminated ÷ number of layers set × 100 (%)

[0076] 5 corresponds to normal operation of the die device 3 and the lamination device 5. "Stacking rate 90 to 100%" corresponds to operation of the die device 3 and the lamination device 5 from just before the completion of the laminated core 29 to the removal of the alignment jig 25 having the completed laminated core 29 and the setting of the next alignment jig 25, and then the stop of the lamination device 5.

[0077] Although the lamination ratio is divided into two sections, the number of sections can be increased and the ranges of each section can be set to be equal or unequal.

[0078] In FIG. 5, the indication of "press" means the pressing step S1, and "lamination" means the lamination step S2.

[0079] The indication of "stop" in FIG. 5 means that the pressing step S1 or the lamination step S2 is stopped.

[0080] The indications of "high", "medium", and "low" in the "press" column in Fig. 5 mean a high press speed value, a medium press speed value, and a low press speed value. These speed values ​​are set according to the capacity of the die device 3.

[0081] 5, the indications of “high”, “medium”, and “low” in the “Lamination” column mean a high-speed lamination value, a medium-speed lamination value, and a low-speed lamination value. These speed values ​​are set according to the capacity of the lamination device 5.

[0082] The low press speed value is a value at which the shot speed of the punch of the die device 3 is relatively slower than the high press speed value and the medium press speed value. The low lamination speed value is a value at which the shot speed of the punch of the lamination device 5 is relatively slower than the high lamination speed value and the medium lamination speed value. The low lamination speed value is set according to the low press speed value. When set according to the low press speed value, the low lamination speed value is set to be the same as or close to the low press speed value.

[0083] The high press speed value is a value at which the shot speed of the punch of the die device 3 is relatively faster than the low press speed value and the medium press speed value. The high lamination speed value is a value at which the shot speed of the punch of the lamination device 5 is relatively faster than the low lamination speed value and the medium lamination speed value. The high lamination speed value is set according to the high press speed value, like the low lamination speed value.

[0084] The medium press speed value is an intermediate value between the high press speed value and the low press speed value for the shot speed of the punch of the die device 3. The intermediate value may be an even median value between the low press speed value and the high press speed value, or a value closer to the low press speed value or closer to the high press speed value.

[0085] The lamination medium speed value is an intermediate value between the lamination high speed value and the lamination low speed value for the shot speed of the punch of the lamination device 5. The intermediate value can be an even median value between the lamination low speed value and the lamination high speed value, or a value closer to the lamination low speed value or closer to the lamination high speed value. The lamination medium speed value is set according to the press medium speed value, like the lamination low speed value.

[0086] In this embodiment, the speed of the pressing process S1 by the die device 3 and the speed of the lamination process S2 by the lamination device 5 are set to the same maximum speed, i.e., the press high speed value and the lamination high speed value. The speed of the pressing process S1 is the time required for one shot of the punch in the press processing, and in this embodiment, it is the number of shots per minute of the punch in the press processing. The speed of the lamination process S2 is the time required for one shot of the punch of the cut press that separates the arc-shaped core piece 33 from the carrier-attached veneer 19, and in this embodiment, the number of shots per minute of the punch of the lamination cut press is (spm).

[0087] The speed of the pressing step S1 may be the speed at which the veneer 19 with a carrier is discharged from the die device 3. The speed of the laminating step S2 may also be the speed at which the veneer 19 with a carrier is drawn in.

[0088] In this embodiment, the speed of the pressing process S1 and the speed of the lamination process S2 are set to a low pressing speed value and a low lamination speed value as the minimum speeds, and a medium pressing speed value and a medium lamination speed value are set as speeds intermediate between the maximum and minimum speeds.

[0089] As shown in Fig. 5, when the stacking ratio is 0 to 90%, and the vertical position of the carrier-attached veneer 19 is detected by the fourth sensor 45d, the speed of the pressing step S1 and the stacking step S2 are controlled to the high-speed pressing value and the high-speed stacking value. This control is the standard operation.

[0090] The time required to remove the alignment jig 25 on which the laminated cores 29 are stacked and to set the next alignment jig 25 is about 20% when converted into a stacking rate. Accordingly, the stacking process S2 after the alignment jig 25 is set starts when the fifth sensor 45e or the sixth sensor 45f detects the vertical position of the veneer 19 with carrier.

[0091] If for some reason the vertical position of the veneer board 19 with a carrier exceeds the upper or lower limit, the first sensor 45a or the seventh sensor 45g detects this, and the pressing step S1 and the laminating step S2 are stopped.

[0092] When the pressing process S1 or the lamination process S2 is in operation, the second sensor 45b to the sixth sensor 45f detect the vertical position of the carrier-attached veneer 19 within the lamination rate range of 0 to 90%, and the pressing process S1 and the lamination process S2 are controlled to high, medium, or low as shown in Figure 5.

[0093] In this case, during operation with a lamination ratio of 0 to 90%, the pressing high speed value and lamination high speed value are maintained by making the vertical position of the veneer 19 with a carrier detected by the fourth sensor 45d.

[0094] When the amount of sagging increases due to an error in speed between the pressing step S1 and the lamination step S2 and the fifth sensor 45e detects the vertical position of the veneer sheet 19 with a carrier, the pressing step S1 is changed to a medium pressing speed value. This makes the speed of the lamination step S2 faster relative to the speed of the pressing step S1, and the amount of sagging of the veneer sheet 19 with a carrier decreases.

[0095] If the sagging amount further increases and the sixth sensor 45f detects the vertical position of the veneer with a carrier 19, the pressing process S1 is further changed to the low pressing speed value. This makes the speed of the laminating process S2 faster relative to the speed of the pressing process S1, and the sagging amount of the veneer with a carrier 19 decreases more rapidly.

[0096] Conversely, when the amount of sagging decreases and the third sensor 45c detects the vertical position of the veneer board 19 with a carrier, the lamination process S2 is changed to a medium lamination speed value. With this change, the speed of the lamination process S2 becomes slower relative to the speed of the press process S1, and the amount of sagging of the veneer board 19 with a carrier increases.

[0097] When the amount of sagging is further decreased and the second sensor 45b detects the vertical position of the veneer with carrier 19, the lamination process S2 is further changed to the lamination low speed value. With this change, the speed of the lamination process S2 becomes further slower relative to the speed of the pressing process S1, and the amount of sagging of the veneer with carrier 19 increases more rapidly.

[0098] In this way, during operation at a lamination rate of 0 to 90%, the vertical position of the veneer 19 with a carrier is detected by the fourth sensor 45d, thereby maintaining the press high speed value and lamination high speed value.

[0099] Therefore, the manufacturing efficiency of the laminated core 29 can be improved.

[0100] On the other hand, before the lamination process S2 completes the formation of the laminated core 29, for example when the lamination rate reaches 90%, the press process S1 is changed to the low press speed value. This change to the low press speed value occurs when the vertical position of the veneer sheet 19 with a carrier is detected by the second to fifth sensors 45b to 45e. When the vertical position of the veneer sheet 19 with a carrier is detected by the sixth sensor 45f, the low press speed value is maintained as it is.

[0101] This control causes the speed of the lamination process S2 to become faster relative to the speed of the pressing process S1, and the amount of slack in the veneer plate 19 with a carrier is reduced to a set value. In this embodiment, the reduction to the set value is detected by the second sensor 45b.

[0102] When the amount of slack in the veneer 19 with a carrier is reduced to the set value, the speed of the laminating step S2 is set to the laminating low speed value set in accordance with the press low speed value.

[0103] When this control is performed, if the vertical position of the carrier-attached veneer 19 has already been detected by the second sensor 45b, the pressing process S1 is simply changed to the low press speed value and the operation is controlled, and the stacking low speed value of the stacking process S2 is maintained as is.

[0104] In this state, if the lamination process S2 is stopped while continuing the operation of the pressing process S1 in order to remove and set the alignment jig 25, the vertical position of the carrier-attached veneer 19 will be close to the lower limit of the allowable set range (the amount of sagging will be close to the upper limit of the allowable range).

[0105] Therefore, by utilizing the time it takes for the vertical position of the carrier-attached veneer 19 to descend to the lower limit within the set range, the alignment jig 25 can be smoothly removed and set while continuing the operation of the pressing process S1.

[0106] 5, when the vertical position of the laminated core 29 is detected by the third sensor 45c immediately before the completion of the formation of the laminated core 29, the speed of the lamination process S2 is controlled at the medium lamination speed value. However, the speed of the lamination process S2 may be set to the high lamination speed value. The low press speed value is maintained until the amount of sagging is reduced to the set value.

[0107] Also, immediately before the completion of the formation of the laminated core 29, when the vertical position is detected by the fourth to sixth sensors 45d to 45f, the speed of the lamination process S2 is controlled at the high lamination speed value.

[0108] In this case, the range in which the amount of sagging of the veneer with carrier 19 decreases due to the medium lamination speed value is set as the medium lamination speed range. The low press speed value is maintained until the amount of sagging falls within the medium lamination speed range.

[0109] Therefore, the amount of sagging can be reduced quickly and smoothly to the set value. Until the amount of sagging of the veneer with carrier 19 is reduced to the set value, the lamination step S2 is performed at the medium lamination speed value and the high lamination speed value, thereby improving the production efficiency.

[0110] In this way, due to the difference in speed between the pressing process S1 and the lamination process S2 between the die device 3 and the lamination device 5, the vertical position of the carrier-attached veneer 19 moves up and down within a set range, allowing the amount of sagging to decrease and increase.

[0111] Just before the completion of the lamination process S2, the speed of the pressing process S1 is relatively slowed down to raise the vertical position of the carrier-attached veneer 19 within a set range, and then, while maintaining the pressing process S1, the alignment jig 25 can be smoothly removed and set until the vertical position of the carrier-attached veneer 19 reaches the lower limit of the set range.

[0112] Therefore, by utilizing the slack of the carrier-attached veneer 19 between the die device 3 and the lamination device 5, the alignment jig 25 on which the laminated iron cores 29 are stacked can be removed and the next alignment jig 25 can be set without stopping the press process S1, and the die device 3 can be protected by suppressing repeated driving and stopping. Moreover, the die device 3 can be set to high, medium, and low and the speed is gradually changed, thereby further improving durability.

[0113] 2, the speed of the pressing step S1 by the die device 3 and the speed of the lamination step S2 by the lamination device 5 can be changed according to the vertical position of the veneer with carrier 19 and the number of stacked annular core pieces 27. Therefore, the vertical position of the veneer with carrier 19 and the amount of sagging can be controlled by shortening the distance between the die device 3 and the lamination device 5.

[0114] 1(B), the winding-type motor core manufacturing apparatus 1A of the comparative example needs to wind the carrier-attached veneer 19 discharged from the die device 3A onto a reel 37. After winding is completed, the reel 37 is set in the lamination device 5A to execute the lamination process, and the laminated core is received from the lamination device 5A by the welding device 11A for welding.

[0115] This requires setup for reel replacement during the pressing process and lamination process, which inevitably reduces productivity.

[0116] In addition to the comparative example, there is also an example in which the die device 3 and the lamination device 5 are connected. In this example, the loop controller 7 employed in the embodiment does not exist, and the amount of sagging of the veneer 19 with carrier cannot be controlled.

[0117] For this reason, when removing the alignment jig 25 on which the laminated cores 29 are stacked and setting the next alignment jig, it is necessary to stop both the die device 3 and the stacking device 5. Therefore, the die device 3 needs to be repeatedly driven and stopped, which shortens its lifespan.

[0118] [Variation 1] FIG. 6 is a table showing a control example according to the modified example.

[0119] In the first modification, the control during operation at a stacking ratio of 0 to 90% is similar to that described above.

[0120] On the other hand, in the first modification, as shown in FIG. 6, the speed of the lamination step S2 is changed to the set high-speed lamination value before the lamination step S2 is completed, and the operation is controlled.

[0121] This change occurs when the vertical position of the veneer board 19 with a carrier is detected by the second and third sensors 45b, 45c. When the vertical position of the veneer board 19 with a carrier is detected by the fourth to sixth sensors 45d to 45f, the laminating high speed value is maintained as it is.

[0122] By this control, the speed of the laminating step S2 becomes faster relative to the speed of the pressing step S1, and the amount of slack in the veneer with carrier 19 decreases to the set value. The second sensor 45b detects this decrease in the amount of slack to the set value.

[0123] When the amount of slack in the veneer plate 19 with a carrier is reduced to a set value, the speed of the pressing step S1 is set to the set high pressing speed value.

[0124] When this control is performed, if the vertical position of the carrier-attached veneer 19 has already been detected by the second sensor 45b, the lamination process S2 is simply changed to the lamination high-speed value, and the press high-speed value of the press process S1 is maintained as is.

[0125] Therefore, when the laminating step S2 is stopped for removing and setting while continuing the operation of the pressing step S1, the vertical position of the veneer board 19 with a carrier approaches the upper limit of the allowable setting range.

[0126] Therefore, the removal and setting can be smoothly performed while continuing the operation of the pressing step S1.

[0127] As shown in Fig. 6, when the change is made and the amount of slack is detected by the third sensor 45c, the speed of the pressing step S1 is controlled to the medium pressing speed value. However, the speed of the pressing step S1 may be set to the high pressing speed value. The high lamination speed value is maintained until the amount of slack is reduced to the set value.

[0128] Furthermore, when the vertical position of the veneer sheet 19 with a carrier is detected by the fourth to sixth sensors 45d to 45f at the timing when the change control is performed, the speed of the pressing process S1 is controlled at the low press speed value. In this case, the range in which the amount of slack in the veneer sheet 19 with a carrier is reduced by the medium press speed value is set as the medium press speed range. The low press speed value is maintained until the amount of slack falls within the medium press speed range. The low press speed value of the speed of the pressing process S1 is set in a range slower than the medium press speed value.

[0129] Therefore, the amount of sag can be quickly reduced to the set value. After the amount of sag has been reduced to the set value, a sudden increase in the amount of sag can be suppressed, and the production efficiency can be improved by adjusting the press speed and lamination speed.

[0130] [Variation 2] FIG. 7 is a table showing an example of control in the second modification according to the embodiment.

[0131] In the present modified example 2, the control during operation when the stacking ratio is 0 to 90% is similar to that described above.

[0132] On the other hand, in the present modified example 2, the stacking device 5 has a margin in its capacity, and therefore the maximum stacking speed value is set to be higher than the high stacking speed value.

[0133] As shown in FIG. 7, just before the lamination process S2 completes the formation of the laminated iron core 29, the speed of the press process S1 is set to the set high press speed value, and the speed of the lamination process S2 is set to the set maximum lamination speed value.

[0134] The speed of the pressing step S1 is changed when the vertical position of the veneer board 19 with a carrier is detected by the fifth and sixth sensors 45e, 45f. When the vertical position of the veneer board 19 with a carrier is detected by the second to fourth sensors 45b to 45d, the pressing high speed value is maintained as it is.

[0135] When the vertical position of the veneer board 19 with a carrier is detected by the third to sixth sensors 45c to 45f at the timing when the change control of the stacking process S2 is performed, the stacking maximum speed value is set. When the vertical position of the veneer board 19 with a carrier has already been detected by the second sensor 45b, the stacking speed value is changed to the high stacking speed value.

[0136] When the amount of slack in the veneer 19 with a carrier is reduced to the set value, the speed of the laminating step S2 is changed from the maximum laminating speed value to a laminating high speed value set according to the press high speed value while maintaining the press high speed value.

[0137] However, if the vertical position of the veneer board 19 with a carrier has already been detected by the second sensor 45b, the high-speed stacking value is maintained as it is.

[0138] Therefore, the amount of sag can be quickly reduced to the set value. After the amount of sag has been reduced to the set value, a sudden increase in the amount of sag can be suppressed, and the production efficiency can be improved by setting the high press speed value and the maximum lamination speed value. [Explanation of symbols]

[0139] 1 Manufacturing equipment 3. Mold Equipment 5. Stacking device 7 Loop Controller 17 Strip of magnetic steel S1 Press process 19 Veneer with carrier S2 Lamination process 25 Alignment jig 27 Annular core piece 29 Laminated core 33 Arc-shaped core piece 39 Detection unit (detection device) 41 Control unit (control device) 45a~45g 1st~7th sensors

Claims

1. The press process forms a veneer with a carrier, and the lamination process forms a laminated core. In the pressing step, the magnetic steel strip is successively drawn into a die device, and the carrier-attached single plate is processed and discharged by pressing. In the lamination step, the discharged veneers with carriers are successively drawn into a lamination device, and the laminated core is formed by positioning and laminating the annular core pieces on an alignment jig that is set in advance so as to be replaceable, allowing the vertical position of the veneer with a carrier to move up and down within a set range according to the amount of slack of the veneer with a carrier due to the difference between the speed of the pressing process and the speed of the lamination process between the die device and the lamination device; Just before the lamination step is completed, the speed of the pressing step is relatively slowed down to raise the vertical position within the set range, and then while continuing the pressing step, the vertical position is lowered until it reaches the lower limit of the set range, and the alignment jig on which the laminated iron cores are stacked is removed and a next alignment jig is set. A manufacturing method for a motor core.

2. A method for manufacturing a motor core according to claim 1, before the lamination step is completed, the speed of the pressing step is set to a preset low pressing speed value; When the amount of slack of the veneer with the carrier is reduced to a set value, the speed of the lamination process is set to a lamination low speed value set in accordance with the press low speed value. A manufacturing method for a motor core.

3. A method for manufacturing a motor core according to claim 2, comprising the steps of: the press low speed value is maintained until the amount of slack in the veneer with carrier is reduced to the set value, and the speed of the lamination process is set to a lamination medium speed value set in a range faster than the lamination low speed value; A manufacturing method for a motor core.

4. A method for manufacturing a motor core according to claim 3, A range in which the amount of slack of the veneer with carrier is reduced by the intermediate lamination speed value is set as an intermediate lamination speed range; the press low speed value is maintained until the slack amount of the veneer with the carrier reaches the medium lamination speed range, while the lamination speed is set to a high lamination speed value set in a range faster than the medium lamination speed value; A manufacturing method for a motor core.

5. A method for manufacturing a motor core according to claim 1, before the lamination process is completed, the speed of the lamination process is set to a preset lamination high speed value; When the amount of slack in the carrier-attached veneer is reduced to a set value, the speed of the pressing step is set to a set high-speed pressing value. A manufacturing method for a motor core.

6. A method for manufacturing a motor core according to claim 5, the speed of the pressing step is set to a medium pressing speed value set in a range slower than the high pressing speed value while maintaining the high lamination speed value until the amount of slack of the veneer with carrier is reduced to the set value; A manufacturing method for a motor core.

7. A method for manufacturing a motor core according to claim 6, comprising the steps of: A range in which the amount of slack of the carrier-attached veneer is reduced by the medium press speed value is set as a medium press speed range; the speed of the pressing step is set to a low press speed value set in a range slower than the medium press speed value while maintaining the high lamination speed value until the amount of slack of the veneer with carrier reaches the medium press speed range; A manufacturing method for a motor core.

8. A method for manufacturing a motor core according to claim 1, before the lamination step is completed, the speed of the press step is set to a preset high press speed value and the speed of the lamination step is set to a preset maximum lamination speed value; When the amount of slack of the veneer with the carrier is reduced to a set value, the press high speed value is maintained while the speed of the lamination process is set to a lamination high speed value set in accordance with the press high speed value. A manufacturing method for a motor core.

9. a die device which sequentially draws in a strip of magnetic steel sheet and processes and discharges a veneer with a carrier by pressing; a lamination device for sequentially drawing in the discharged veneers with carriers and forming a laminated core in which annular core pieces are positioned and laminated on an alignment jig that is set in advance so as to be replaceable; a detection device for detecting whether the vertical position of the veneer with a carrier moves up and down within a set range depending on the amount of slack of the veneer with a carrier due to the difference between the speed of operation of the die device and the speed of operation of the lamination device between the die device and the lamination device; a control device which, immediately before the completion of the formation of the laminated core, relatively slows down the speed of the operation of the die device to raise the vertical position within the set range, and then, while continuing the operation of the die device, stops the lamination device before the vertical position reaches the lower limit of the set range, thereby removing the alignment jig on which the laminated core is stacked, and enabling the setting of the next alignment jig; A motor core manufacturing device equipped with:

10. The motor core manufacturing apparatus according to claim 9, The detection device includes an upper sensor that detects that the vertical position of the veneer with a carrier rises and the amount of sagging decreases to a set value, and a lower sensor that detects that the vertical position of the veneer with a carrier falls and the amount of sagging increases above the set value. Motor core manufacturing equipment.

11. The motor core manufacturing apparatus according to claim 10, The detection device includes an upper limit sensor that detects when the vertical position of the veneer with a carrier is outside the upper limit of the set range, and a lower limit sensor that detects when the vertical position of the veneer with a carrier is outside the lower limit of the set range, the upper sensor and the lower sensor are located between the upper limit sensor and the lower limit sensor; Motor core manufacturing equipment.

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