Stacked Core Manufacturing Apparatus and Method for Manufacturing a Rotating Electric Machine

Abstract

To provide a laminated core manufacturing apparatus and a method for manufacturing a rotating electric machine, capable of manufacturing a laminated core constituting a highly efficient rotating electric machine at low cost and with good productivity.SOLUTION: The laminated core manufacturing apparatus 100 includes a press machine 10 having a punch 13P and a die 13D for punching out a core piece 5P from a plate material 5 with the plate thickness direction W of the plate material 5 as the punching direction, and a plate material supply device 20 that feeds the plate material to the press machine with the plate thickness direction of the plate material perpendicular to the direction of gravity. The press machine 10 includes a guide 10G that aligns the core pieces 5P ejected from the die 13D in the punching direction by the punch 13P in the punched posture and stacks the core pieces 5P.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This application relates to a laminated core manufacturing apparatus and a method for manufacturing a rotating electrical machine.

Background Art

[0002] In recent years, there has been an increasing demand for higher efficiency in rotating electrical machines such as electric motors and generators. The cores used in rotating electrical machines have hitherto often been composed of laminated cores made of electromagnetic steel sheets with a thickness of about 0.35 mm to 0.5 mm in order to achieve higher efficiency. However, recently, the use of electromagnetic steel sheets with a thickness of 0.35 mm or less has been increasing in order to meet the requirement for even higher efficiency.

[0003] As a means for fixing between the laminations of a plurality of electromagnetic steel sheets constituting a laminated core, a means is widely known in which recesses and projections are provided in the thickness direction of each core piece, and the laminations are fixed by caulking them simultaneously with the punching of the core pieces.

[0004] However, when fixing by caulking the recesses and projections provided in the thickness direction of the core pieces, eddy current loss occurs in the fitting portion, and the efficiency of the rotating electrical machine decreases. Further, when the thickness of the thin plate is 0.3 mm or less, the strength of the caulked portion itself decreases, and it becomes difficult to ensure sufficient fixing strength. Therefore, a method is used in which the laminations between a plurality of core pieces are not fixed simultaneously with punching, but are fixed by a fixing means such as adhesion after punching.

[0005] In the rotating electrical machine described in Patent Document 1, there is disclosed a laminated core manufacturing apparatus that discharges core pieces punched sequentially in the gravitational direction horizontally outside the mold through a cylindrical guide bent from the gravitational direction to the horizontal direction.

[0006] In the same document, among a plurality of slots provided in the core piece, by using the slots defined as specific slots to position the guide and the core piece and discharging them outside the mold, even when the laminations are not fixed by caulking simultaneously with punching, the core pieces can be discharged outside the mold in an aligned state.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0008] In Patent Document 1, the core pieces are punched in the direction of gravity. Since the thickness direction of the plate material coincides with the direction of gravity, the plate material is bent. Especially when using a plate material with a thickness of 0.35 mm or less, in order to suppress the bending, many other guides are required, which complicates the mold and increases the manufacturing cost of the laminated core. Furthermore, when many guides are provided, the resistance in the direction of feeding the material increases, so the plate material is likely to buckle. Especially in the case of thin plates, since the buckling load itself is small, when the resistance in the direction of feeding the plate material increases, buckling frequently occurs, resulting in the problem of deterioration of the productivity of the laminated core.

[0009] This application discloses a technique for solving the above - mentioned problems, and an object thereof is to provide a laminated core manufacturing apparatus and a method for manufacturing a rotating electrical machine that can manufacture a laminated core constituting a rotating electrical machine at low cost and with high productivity.

Means for Solving the Problems

[0010] The laminated core manufacturing apparatus disclosed in this application is a press machine including a punch and a die for punching core pieces from a plate material with the thickness direction of the plate material as the punching direction, a plate material supply device for supplying the plate material to the press machine with the thickness direction of the plate material perpendicular to the direction of gravity, the press machine includes a guide for aligning the core pieces discharged from the die in the punching direction by the punch and laminating them into a group of core pieces while maintaining the punched posture. The guide has both inner surfaces that contact the core pieces in the direction of gravity, and the both inner surfaces and the core pieces Obliquely opposite in the direction of gravity So as to support the iron core piece with respect to the gravitational direction on the surfaces of the core pieces Above in the gravitational direction are open.

Advantages of the Invention

[0011] According to the laminated core manufacturing apparatus and the method for manufacturing a rotating electrical machine disclosed in the present application, it is possible to provide a laminated core manufacturing apparatus and a method for manufacturing a rotating electrical machine that can manufacture a laminated core constituting a highly efficient rotating electrical machine at low cost and with high productivity.

Brief Description of the Drawings

[0012]

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Embodiments for Carrying Out the Invention

[0013] Embodiment 1 Hereinafter, a laminated core manufacturing apparatus and a method for manufacturing a rotating electrical machine according to Embodiment 1 will be described with reference to the drawings. FIG. 1 is a front schematic view of a laminated core manufacturing apparatus 100. FIG. 2 is a perspective view of a press 10 that constitutes the laminated core manufacturing apparatus 100. FIG. 3 is a side view of the press 10. FIG. 4 is a schematic cross-sectional view of a main part of the press 10 and is a cross-sectional view taken along line A-A in FIG. 3. FIG. 5 is a cross-sectional view taken along line B-B in FIG. 4. FIG. 6 is a cross-sectional view taken along line C-C in FIG. 4. FIG. 7 is a detailed view of the portion surrounded by the circle D in FIG. 6. In the following description, since the punching direction of the core piece P by the punch 13P and the thickness direction of the plate material 5 are always the same, the same reference sign W is used.

[0014] The laminated core manufacturing apparatus 100 shown in FIG. 1 includes a press 10 that punches a core piece from a plate material 5 and a material supply device 20 that supplies the plate material 5 to the press 10. The material supply device 20 includes an uncoiler 21 that rotatably mounts the plate material 5 wound in a coil shape and supplies the plate material 5 to the press 10 while feeding it out, and a plurality of pairs of rollers 22 that guide the plate material while sandwiching it.

[0015] The press 10 includes a mounting table 11, a frame 12 installed on the mounting table 11, a die 13 fixed in the frame 12 for punching a core piece 5P from the plate material 5, a guide 10G that aligns the punched core pieces 5P in the punching direction W and stacks the core piece 5P groups in sequence while maintaining the punched posture, a material feeding device 14 that feeds the plate material 5 to the die 13 in a forward direction, a plate material guide 15 that guides the plate material 5 from the material feeding device 14 to the die 13, and a motor 16 and a crank cam 17 that drive the punch of the die 13.

[0016] Next, the details of the mold 13 will be described. As shown in FIGS. 1 and 4, the mold 13 is composed of a punch 13P, a die 13D, a first plate 13A, and a second plate 13B. The punch 13P is fixed to the first plate 13A, and the die 13D is fixed to the second plate 13B. Further, the first plate 13A is fixed to a slide 18 connected to a crank cam 17, and the second plate 13B is fixed to a bolster 19. Also, the bolster 19 is fixed to the frame 12. The slide 18 is connected to the crank cam 17, and by rotating the crank cam 17 with the motor 16, the slide 18 can be driven in the horizontal direction H (the left-right direction in FIG. 1).

[0017] In this way, by driving the motor 16 of the press 10, the slide 18 is relatively moved in the horizontal direction H with respect to the frame 12 via the crank cam 17, the plate material 5 is punched in one direction of the plate thickness direction W by the punch 13P and the die 13D, and further, as shown in FIG. 5, the punched core piece 5P is pushed into the die 13D.

[0018] As shown in FIG. 1, the coiled plate material 5 is placed on the uncoiler 21, and the plate material 5 is supplied to the press 10. The plate material 5 is fed by a predetermined length by the material feeder 14 and then punched into the shape of the core piece 5P by the mold 13. At this time, the plate material 5 is supplied in the gravitational direction G. As a result, the plate thickness direction W of the plate material 5 is perpendicular to the gravitational direction G, that is, in the horizontal direction H.

[0019] The punched plate material 5 is again fed by the material feeder 14 by a predetermined length, and the next core piece 5P is punched by the die 13. By repeating this operation, the group of core pieces 5P is laminated in the left direction in FIG. 1 within the guide 10G. At this time, as shown in FIG. 6, the core piece 5P discharged from the die 13 has both end portions 5PYE of the yoke portion 5PY supported by both inner side surfaces 10GS of the guide 10G, and is sequentially pushed out to the left side in FIG. 1 within the guide 10G. Also, at this time, the angle formed by both inner side surfaces 10GS of the guide 10G and the angle formed by both end portions 5PYE of the yoke portion 5PY of the core piece 5P are both equal to the angle α. Therefore, the core piece 5P is held straight by the guide 10G with the tooth portion 5PT facing the gravity direction G.

[0020] Here, a configuration in which the slide 18 is driven by a general crank cam 17 is shown, but as a means for driving the slide 18, a drive source such as a hydraulic cylinder or a ball screw may be used. Also, by appropriately arranging a plate material guide 15 between the material feeder 14 and the die 13, it is possible to suppress the wobbling of the plate material 5 and stably feed the plate material 5.

[0021] By repeating the above cycle, the core pieces 5P are punched out from the plate material 5, and the already punched core pieces 5P are continuously pushed out to the left direction in FIG. 6. The pushed-out core piece 5P has a configuration in which at least a part of the outer peripheral surface of the core piece 5P is in contact with the gravity direction G with respect to the guide 10G. Through this guide 10G, the group of core pieces 5P can be discharged to the outside of the press 10 and made to be in a state where they can be taken out.

[0022] Here, it is desirable that the core piece 5P punched by the punch 13P is punched out laterally and discharged straight. Compared with the case of horizontally supplying a plate material and punching out a core piece in the gravity direction G by a punch, and then further bending it by 90 degrees by a guide and taking it out as in the prior art document, there is no "jamming" or "pinching", and there is an effect that the productivity of the laminated core can be improved.

[0023] In addition, by providing a guide 10G that is in contact with at least a part of the outer peripheral surface of the core piece 5P in the gravitational direction G, even if the core piece 5P itself has no guide groove or hole, the core piece 5P can be guided and discharged outside the press machine 10. Therefore, there are no shape restrictions on the core piece 5P, and the effect of improving the design freedom is achieved.

[0024] When punching out the core piece in the gravitational direction G, the core piece will move in the gravitational direction G. In this case, a guide cannot be provided in the gravitational direction G. Therefore, the punched-out core piece will fall freely and get caught in a state inclined with respect to the bent guide. When the punched-out core pieces are stacked in this state, excessive force acts on the guide or the die, leading to failures such as breakage and deformation, and deteriorating productivity.

[0025] To avoid this, a method of making the width of the guide smaller than the width of the core piece and holding the core piece by the frictional force of the guide can be considered. However, in press working, a lubricant is usually applied to extend the die life. In this case, the frictional force is small and unstable. As a result, the width of the guide needs to be adjusted frequently, and there is a problem of deteriorating productivity.

[0026] Also, when trying to continuously move the core piece with a frictional force generated between the guide and the stacked core pieces, the wear of the guide is large and it needs to be replaced frequently, which deteriorates the productivity of the laminated core. Comparing with the prior art documents that punch out in the gravitational direction and then discharge in the direction perpendicular to the gravitational direction, in the present application, the adjustment frequency and replacement frequency of the guide can be reduced, and the effect of improving the productivity of the laminated core is achieved.

[0027] In addition, according to the laminated core manufacturing apparatus 100, since the group of core pieces 5P laminated perpendicular to the gravitational direction G (horizontal direction H) can be discharged, there is an effect of reducing the height of the press 10. On the other hand, when punching in the vertical direction as in the prior art document, it is necessary to provide a space for discharge downward, so the height of the press increases. As the height of the apparatus increases, the rigidity of each part becomes weak, so there is a problem that the vibration and noise of the press increase.

[0028] Also, in this case, practical problems such as the inability to carry the apparatus into the building may occur. Furthermore, in order to take out the core pieces, it is necessary to crawl under the press to take them out, so the workability is poor and the configuration of the equipment is very difficult. Even if a core piece discharge device is installed under the press, there is a problem of poor maintainability. On the other hand, according to the laminated core manufacturing apparatus 100 according to Embodiment 1, by directly discharging the core pieces 5P in the horizontal direction H, work can be performed beside the apparatus, so the workability is good. In addition, since the equipment for taking out the laminated core is also easy to configure, there is an effect of improving the productivity of the laminated core.

[0029] As shown in FIG. 4, a pressing device 10PS may be provided on the side of the guide 10G opposite to the die 13 side, and the group of core pieces 5P discharged from the die 13 may be pressed toward the die 13 side. By pressing the group of punched core pieces 5P by the pressing device 10PS, the posture of each core piece 5P becomes more stable and the inclination of each core piece 5P becomes smaller, so the risk of getting caught in the guide 10G is further reduced, and there is an effect of improving the productivity of the laminated core.

[0030] FIG. 7 is a schematic diagram showing the positional relationship among the die 13, the plate material 5, and the plate material guide 15. Focusing on the orientation of the plate material 5, the plate thickness direction W is perpendicular to the gravitational direction G. Therefore, the plate material 5 sags due to its own weight. As a result, the plate material 5 does not bend, so the possibility of buckling occurring in the plate material 5 is suppressed, and there is an effect of improving the productivity of the laminated core.

[0031] FIG. 8 is a schematic diagram showing a comparative example in which a plate material is conveyed in the horizontal direction to punch out core pieces. As shown in FIG. 8, when the self-weight direction (gravity direction G) coincides with the plate thickness direction W, in particular, for a plate material 5 with a thickness of 0.35 mm or less, the plate material is greatly deflected by its own weight, so buckling is likely to occur in the plate material. By providing a plurality of guides in the plate thickness direction W, the number of support points can be increased and the load can be dispersed. However, if the number of plate material guides 15 is increased, the load required for feeding the plate material also increases, so the effect may be offset.

[0032] Also, since the load required for material feeding increases, slipping occurs in the material feeding device, so there is a possibility that the plate material is not properly fed and punching defects occur. On the other hand, in the first embodiment, since the gravity direction G with the self-weight and the plate thickness direction W are perpendicular, the number of plate material guides 15 can be reduced, the load required for feeding the plate material 5 can be reduced, and the possibility of slipping occurring in the material feeding device 14 can also be reduced, so there is an effect of improving the productivity of the laminated core.

[0033] In the first embodiment, since the feeding direction of the plate material 5 coincides with the direction in which the self-weight acts, there is no frictional force applied to the plate material guide 15 due to the self-weight, and the feeding load corresponding to the force applied in the feeding direction due to the self-weight can be reduced. Therefore, the load required for material feeding can be further reduced, and the possibility of slipping occurring in the material feeding device 14 can be reduced, so there is an effect of improving the productivity of the laminated core.

[0034] FIG. 9 is a detailed view of the portion surrounded by the circle D in FIG. 4. FIG. 9A is a view showing the state when the plate material 5 is being fed. FIG. 9B is a view showing the state immediately before pressing the core piece 5P. FIG. 9C is a view showing the state immediately after pressing the core piece 5P. As shown in FIGS. 1, 9A to 9C, an upper cutter 10CUP as a cutter is attached to the bolster 19, and a lower cutter 10CDW as a cutter is attached to the slide 18. When the plate material 5 is fed, the plate material 5 is fed between the upper cutter 10CUP and the lower cutter 10CDW (FIG. 9A). Then, when the core piece 5P is punched (FIG. 9B), in conjunction with this operation, the plate material 5 is cut by the upper cutter 10CUP and the lower cutter 10CDW by approximately the feed pitch (FIG. 9C).

[0035] By providing the upper cutter 10CUP and the lower cutter 10CDW configured as described above, the plate material 5 after punching the core piece 5P can be finely cut, so that there is an effect that it becomes easy to collect the scrap of the plate material 5.

[0036] Further, since the upper cutter 10CUP is attached to the bolster 19 and the lower cutter 10CDW attached to the slide 18 is installed on the feed direction side of the plate material 5, the shredded scrap naturally falls by its own weight in a direction away from the lower cutter 10CDW. Therefore, compared with the case of reciprocating the two cutters in the gravitational direction G, troubles such as the scrap material sticking to and biting into the lower cutter 10CDW can be suppressed, and there is an effect of improving the productivity of the laminated core.

[0037] FIG. 10 is a front schematic view of an application example of the laminated core manufacturing apparatus according to Embodiment 1. The configuration of the laminated core manufacturing apparatus 100 is substantially the same as the laminated core manufacturing apparatus 100 described so far. In FIG. 10, the punching direction of the core piece 5P is not completely perpendicular to the gravitational direction G. In this way, it is only necessary that the punching direction of the core piece 5P does not coincide with the gravitational direction G and is different. Since the punching direction of the core piece 5P is different from the gravitational direction G, at least a part of the punching direction of the core piece 5P includes a component perpendicular to the gravitational direction G, so that the same effect as the effect described so far can be obtained. In this case, the supply direction F of the plate material 5 to the press 10 also tilts.

[0038] FIG. 11 is a schematic diagram showing the balance of forces acting on the group of core pieces 5P on the guide 10G. Here, let the angle formed by the longitudinal direction of the guide 10G (the discharge direction of the core pieces 5P) and the horizontal direction be θ, the weight of the group of core pieces 5P be M, and the gravitational acceleration be g. Regarding the component of the force in the longitudinal direction of the guide 10G, Mg*sinθ, and the component of the force in the direction perpendicular to the longitudinal direction of the guide 10G, Mg*cosθ, it is desirable that the component of the force in the longitudinal direction of the guide 10G is smaller.

[0039] When the component of the force in the longitudinal direction of the guide 10G becomes large, since the longitudinal direction of the guide approaches the gravitational direction G as in the prior art documents, it becomes difficult to obtain the effects of the present application. That is, it is desirable that θ is in the range within 45° up and down from the horizontal direction.

[0040] Further, when the guide 10G is inclined so that the advancing direction side of the group of core pieces 5P faces downward, if the force Mg*sinθ that tends to slide is large with respect to the holding force μMg*cosθ due to the friction acting on the group of core pieces 5P, the group of core pieces 5P will slide with respect to the guide 10G, and it will be difficult to obtain the effects of the present application. Therefore, it is desirable that tanθ < μ. Generally, since the friction coefficient is known to take a value of about 0.1 to 0.9, it is desirable that tanθ < about 0.9.

[0041] In addition, in the first embodiment, one plate material 5 wound in a coil shape was rotatably attached to the material supply device 20. However, if a plurality of plate materials 5 wound in a coil shape are used, it is also possible to simultaneously punch out a plurality of core pieces 5P with a pair of punches and dies. Also, in this embodiment, an example of manufacturing a laminated core of a rotating electrical machine was shown. However, the laminated core manufacturing apparatus 100 can also be used for manufacturing cores such as transformers.

[0042] Embodiment 2. Hereinafter, the laminated core manufacturing apparatus and the manufacturing method of the rotating electrical machine according to the second embodiment will be mainly described with respect to the parts different from the first embodiment. FIG. 12 is a front schematic diagram of the laminated core manufacturing apparatus 200. FIG. 13 is a plan view of the laminated core manufacturing apparatus 200 shown in FIG. 12. In the first embodiment, the plate material 5 was supplied to the press machine 10 in the gravity direction G from above, but in this embodiment, the plate material 5 is different in that it is supplied to the press machine 210 with the longitudinal direction (feeding direction) facing the horizontal direction H. The point that the plate material 5 is supplied to the press machine 210 with the plate thickness direction W of the plate material 5 perpendicular to the gravity direction G is the same as in the first embodiment.

[0043] The uncoiler 221 of the material supply device 220 has a rotation axis facing the gravity direction G. The plate material 5 unwound from the uncoiler 221 is supplied to the mold 213 by the material feeding device 214 of the press machine 210 with the feeding direction of the plate material 5 perpendicular to the gravity direction G (horizontal direction H) and the width direction of the plate material 5 facing the gravity direction G.

[0044] Therefore, since the plate material 5 does not bend due to its own weight, the possibility of buckling occurring in the plate material 5 is suppressed, and there is an effect of improving the productivity of the laminated core.

[0045] Also, as in the first embodiment, the number of rollers 222 for guiding the plate material 5 can be reduced, so there is an effect of improving the productivity of the laminated core. Further, since the feeding direction of the plate material 5 and the gravity direction G are perpendicular, the height of the laminated core manufacturing apparatus 200 is reduced, and there is an effect of miniaturizing the laminated core manufacturing apparatus 200. Also, from the material supply device 220 to the mold 213 via the material feeding device 214, the thickness direction of the plate material 5 is perpendicular to the gravity direction G.

[0046] Therefore, also in the process from the material supply device 220 to the supply to the mold 213, since the plate material 5 does not bend due to its own weight, the possibility of buckling occurring in the plate material 5 is suppressed, and there is an effect of improving the productivity of the laminated core.

[0047] Embodiment 3. Hereinafter, the laminated core manufacturing apparatus and the manufacturing method of the rotating electric machine according to Embodiment 3 will be described centering on the parts different from Embodiment 1. FIG. 14 is a front schematic view of the press 310 according to Embodiment 3. In Embodiment 1, the fixed bolster 19 and the moving slide 18 were combined. However, in Embodiment 3, two moving slides 318A and 318B are used, and both are slid in the horizontal direction H and driven in opposite phases, so that the vibration forces applied to the press 310 by the operations of the slides 318A and 318B can be canceled out. By reducing the vibration force applied to the press 310, the punching accuracy of the core piece 5P can be stabilized, and the laminated core can be made more accurate. In addition, the vibration and noise of the press 310 are reduced, and the manufacturing environment can be made quieter.

[0048] FIG. 15 is a schematic view of the die operation of the press 310 according to Embodiment 3. FIG. 15A is a schematic view showing the state before punching the core piece 5P. FIG. 15B is a schematic view showing the state when punching the core piece 5P. FIG. 15C is a schematic view showing the state in which the group of core pieces 5P are punched out and discharged. As shown in FIG. 14, a first plate 313A is attached to the slide 318A, and a second plate 313B is attached to the slide 318B. The first plate 313A and the second plate 313B are movable in the horizontal direction facing each other.

[0049] A first punch 313PA, a first die 313DA, and a first guide 310GA are attached to the first plate 313A, and a second punch 313PB, a second die 313DB, and a second guide 310GB are attached to the second plate 313B.

[0050] As shown in Fig. 15A, with respect to the plate material 5 supplied from above, as shown in Fig. 15B, the first plate 313A and the second plate 313B are operated in a direction approaching each other, so that two core pieces 5P are simultaneously punched out by the first punch 313PA and the first die 313DA, and the second punch 313PB and the second die 313DB. By repeating this operation, the core pieces 5P are sequentially discharged toward the first guide 310GA and the second guide 310GB. The first guide 310GA and the second guide 310GB extend in the horizontal direction and in opposite directions to each other.

[0051] The two core pieces 5P punched out simultaneously are discharged separately in the left - right direction as shown in Fig. 15C. Compared with the case where they are discharged from only one side, the space for taking out can be increased, so that it is easier to take out the core pieces 5P. Therefore, it has the effect of improving the productivity of the laminated core.

[0052] Embodiment 4. Hereinafter, the laminated core manufacturing apparatus and the manufacturing method of the rotating electrical machine according to Embodiment 4 will be described centering on the parts different from Embodiment 1. Fig. 16 is a schematic cross - sectional view of the main part of the laminated core manufacturing apparatus 400 according to Embodiment 4. Fig. 17 is a cross - sectional view taken along the line E - E of Fig. 16. Fig. 18 is a cross - sectional view taken along the line F - F of Fig. 16. The group of core pieces 5P sequentially discharged horizontally along the guide 10G is supported by both end portions 5PYE of the yoke portion 5PY on both inner side surfaces 10GS of the guide 10G. Above the guide 10G, a second pressing portion 410PS is provided, and by pressing the group of core pieces 5P in the gravitational direction G, the alignment of the group of core pieces 5P is enhanced. The guide 10G is provided with an application nozzle 6N and a hot air blower 40 as an adhesion device. The heat - curable adhesive 61 is applied to the central portion in the circumferential direction of the yoke portion 5PY of the aligned group of core pieces 5P by the application nozzle 6N.

[0053] The group of core pieces 5P coated with the adhesive 61 is sequentially discharged in the left direction of FIG. 16 and heated by the warm air supplied from the warm air blower 40 through the air nozzle 41 in the aligned state, and the adhesive 61 is cured. The group of core pieces 5P with the cured laminations fixed is cut to a predetermined length by the cutting tool 70 to form the laminated core 50, and is conveyed to the next process by the belt conveyor 80.

[0054] Here, since the laminated core 50 is discharged with the laminations fixed, the conveyance to the subsequent process becomes easy, which has the effect of improving the productivity of the subsequent process. Also, since the apparatuses can be arranged in the horizontal direction, there is an effect of improving the maintainability of the laminated core manufacturing apparatus 400. Further, since the lamination direction of the laminated core 50 is perpendicular to the gravity direction G, there is no possibility of gaps or tilting between the laminations of the laminated core 50 due to the influence of gravity, so there is an effect of improving the shape accuracy of the laminated core 50 while stabilizing the fixing strength.

[0055] In the above example, the heat-curing type adhesive 61 was used for explanation, but any type of adhesive may be used as long as the laminations can be fixed. When a room temperature-curing type or two-component mixing type adhesive is used, since no curing means is required, there is an effect of improving the productivity of the laminated core 50. Also, when a photo-curing type adhesive is used, the adhesive can be cured continuously in the same manner by using a UV light instead of the warm air blower 40.

[0056] FIG. 19A is a diagram showing another example of the bonding method. FIG. 19B is a cross-sectional view taken along the line G-G of FIG. 19A. As shown in FIG. 19B, an adhesive may be applied in advance between the laminations of the core pieces 5P, or an adhesive with low viscosity may be infiltrated between the laminations to bond the surfaces of adjacent core pieces 5P. By adopting such a configuration, there is an effect of further improving the rigidity of the laminated core 50.

[0057] FIG. 20 is a cross-sectional view of a rotating electrical machine 90 assembled using a laminated core manufactured by the laminated core manufacturing apparatus described so far. The rotating electrical machine 90 is used as a motor or a generator. The rotating electrical machine 90 includes a stator 90A and a rotor 90B rotatably supported with its outer peripheral surface facing the inner peripheral surface of the stator 90A. An insulating member 81 is covered on a laminated core 50 formed by laminating iron core pieces 5P and adhered by fixing means, and a coil 82 is wound thereon. The coil 82 is electrically connected by a connection member 83 and connected to a current control device such as a power supply or an inverter. A plurality of annularly arranged laminated cores 50 are fixed in a frame 84, and are supported by a shaft 87 supported by bearings 86 provided on the frame 84 and a bracket 85 closing an opening of the frame 84, respectively, and are relatively rotatably supported.

[0058] A rotor core 88 and a magnet M are fixed to the shaft 87. By passing an alternating current through the coil 82 with such a configuration, a rotating magnetic field is generated, an attractive force is generated between the magnet M and the laminated core 50, torque is applied to the shaft 87, and electrical energy can be converted into rotational energy. Here, since the laminated core 50 in which the iron core pieces 5P are fixed by adhesion does not have electrical short circuits between the laminations, iron loss can be reduced, and there is an effect of improving the efficiency of the rotating electrical machine 90.

[0059] Further, since the laminated core 50 manufactured using the laminated core manufacturing apparatus according to the present embodiment has the lamination direction of the iron core pieces 5P perpendicular to the gravity direction G, gaps are not formed between the laminations or the laminated core 50 is not tilted due to the influence of gravity. Therefore, the fixing strength between the laminations of the iron core pieces 5P is stabilized, the shape accuracy of the laminated core 50 is improved, and the strength is improved. Therefore, the roundness of the inner diameter of the stator core of the rotating electrical machine 90 is high. Therefore, there is an effect of suppressing the cogging torque and torque ripple of the rotating electrical machine 90.

[0060] Embodiment 5. Hereinafter, the laminated core manufacturing apparatus and the manufacturing method of the rotating electrical machine according to Embodiment 5 will be described centering on the parts different from Embodiment 4. FIG. 21 is a schematic cross-sectional view of the main part of the laminated core manufacturing apparatus 500 according to Embodiment 5. FIG. 22 is a cross-sectional view taken along the line H-H of FIG. 21. In Embodiment 4 and this Embodiment 5, the method of fixing the group of core pieces 5P constituting the laminated core is different. Instead of the bonding device of Embodiment 4, a laser head 540 as a welding device is provided. From above the aligned group of core pieces 5P, laser light emitted from the laser head 540 is irradiated, and each layer is welded and fixed.

[0061] The group of core pieces 5P in which the melted part has hardened and the layers are fixed is cut to a predetermined length by the cutting tool 70 to form the laminated core 50, and is conveyed to the next process by the belt conveyor 80.

[0062] In this Embodiment 5, since the layers of the laminated core 50 are firmly fixed by welding, the rigidity of the laminated core 50 is improved, and there is an effect of suppressing the vibration and noise of the rotating electrical machine. In addition, since there is no need to add a member for fixing the layers, there is an effect of producing the laminated core 50 at low cost.

[0063] Embodiment 6. Hereinafter, the laminated core manufacturing apparatus and the manufacturing method of the rotating electrical machine according to Embodiment 6 will be described centering on the parts different from Embodiment 1. This Embodiment 6 is a modification of Embodiment 1. The shape of the core piece and the cross-sectional shape of the guide are different from those of Embodiment 1. FIG. 23 is a view corresponding to the B-B cross-section of FIG. 4 of Embodiment 1 in Embodiment 6. FIG. 24 is a view corresponding to the C-C cross-section of FIG. 4 of Embodiment 1 in Embodiment 6. In the modification shown in FIGS. 23 and 24, the teeth portion 5PT of the core piece 5P is punched in the horizontal direction H. In this case, the core piece 5P is aligned in the guide 10G2 by bringing one side surface of the teeth portion 5PT, the outer peripheral surface of the yoke portion 5PY, and the tip of the teeth portion 5PT into contact with the guide 10G2, and one side surface 5PTS of the teeth portion 5PT becomes the contact surface in the gravity direction G and is supported.

[0064] FIG. 25 is another view corresponding to the B-B cross section of FIG. 4 in Embodiment 1 in Embodiment 6. FIG. 26 is another view corresponding to the C-C cross section of FIG. 4 in Embodiment 1 in Embodiment 6. In this case, in the core piece 5P, the tip of the tooth portion 5PT is on the upper side in the gravity direction G, and both side surfaces of the tooth portion 5PT and the central portion of the outer peripheral surface of the yoke portion 5PY are brought into contact with the guide 10G3 and aligned within the guide 10G3, and the central portion 5PYC of the outer peripheral surface of the yoke portion 5PY serves as a contact surface in the gravity direction G and is supported.

[0065] Thus, in the present application, regardless of the orientation of the core piece 5P, it is sufficient that there is at least a portion that serves as a support portion in the gravity direction G. For the purpose of improving material yield, etc., even when arranging in multiple rows, since the orientation of the core piece 5P with respect to the plate width direction can be arbitrarily set, the material yield can be improved without restrictions on the orientation of the core piece 5P.

[0066] FIG. 27 is a view showing an example of an annular core piece 605P. In the core piece 605P, the outer peripheral surface 605PYO of the yoke portion 605PY serves as a contact surface in the gravity direction G. Thus, even in the case of an annular core piece, if there is a contact surface in the gravity direction G with respect to the guide 10G4, the same effect can be obtained.

[0067] Thus, the present application is effective for the core piece 5P with an arbitrary shape and an arbitrary orientation regardless of the shape of the core piece 5P, the width direction of the material, and the orientation of the core piece 5P. Therefore, compared with the case of passing a guide through the slot portion, there are effects of improving the degree of freedom in the shape of the core piece and the material yield.

[0068] Although various exemplary embodiments and examples are described in the present application, the various features, aspects, and functions described in one or more of the embodiments are not limited to the application of a specific embodiment, but are applicable to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are assumed to be within the scope of the technology disclosed in the present application. For example, it shall include cases where at least one component is modified, added, or omitted, and further, cases where at least one component is extracted and combined with components of other embodiments.

Explanation of Reference Numerals

[0069] 100, 200, 400, 500 Laminated Core Manufacturing Apparatus 10, 210, 310 Press Machine, 10G, 10G2, 10G3, 10G4 Guide 310GA First Guide, 310GB Second Guide, 10CDW Lower Cutter 10CUP Upper Cutter, 10GS Inner Surface, 10PS Pressing Device, 11 Mounting Table 12 Frame, 13, 213 Mold, 13A, 313A First Plate 13B, 313B Second Plate, 13D Die, 313DA First Die 313DB Second Die, 13P Punch, 313PA First Punch 313PB Second Punch, 14, 214 Material Feeding Device, 15 Sheet Material Guide 16 Motor, 17 Crank Cam, 18, 318A, 318B Slide 19 Bolster, 20, 220 Material Supply Device, 21, 221 Uncoiler 22, 222 Roller, 40 Hot Air Blower. 41 Air Nozzle 410PS Second Pressing Portion, 5 Sheet Material, 5P, 605P Core Piece, 50 Laminated Core 540 Laser Head, 5PY, 605PY Yoke Portion, 5PT Teeth Portion 5PYE Both Ends Portion, 5PYC Central Portion, 5PTS One Side Surface, 61 Adhesive 6N Coating Nozzle, 70 Cutting Tool, 80 Belt Conveyor, 81 Insulating Member 82 Coil, 83 Connection Member, 84 Frame, 85 Bracket, 86 Bearing 87 shaft, 88 rotor core, 90 rotating electrical machine, 90A stator, 90B rotor, D circle mark, M magnet.

Claims

1. A press machine comprising a punch and a die for punching core pieces from a plate material with the punching direction being the thickness direction of the plate material, a plate material supply device for supplying the plate material to the press machine with the thickness direction of the plate material being perpendicular to the gravitational direction, wherein the press machine includes a guide for aligning the core pieces discharged from within the die in the punching direction by the punch and stacking them into a group of stacked core pieces while maintaining the punched posture, the guide having both inner surfaces in contact with the core pieces in the gravitational direction, and the guide being open upward in the gravitational direction so as to support the core pieces in the gravitational direction on the surfaces of the core pieces that are obliquely opposed to the both inner surfaces with respect to the gravitational direction, a laminated core manufacturing apparatus.

2. The laminated core manufacturing apparatus according to claim 1, wherein the plate material is supplied to the press machine in the gravitational direction.

3. The laminated core manufacturing apparatus according to claim 1, wherein the plate material is supplied to the press machine in the horizontal direction.

4. The laminated core manufacturing apparatus according to claim 2, further comprising a cutter for cutting the plate material from which the core pieces have been punched in conjunction with the punching operation of the core pieces.

5. The laminated core manufacturing apparatus according to any one of claims 1 to 4, wherein the punch is fixed to a first plate, the die is fixed to a second plate, and the first plate and the second plate are movable in opposite directions horizontally.

6. The press machine, a first punch as the punch and a first die as the die, both fixed to a first plate, a second punch as the punch and a second die as the die, both fixed to a second plate, The laminated core manufacturing apparatus according to any one of claims 1 to 4, wherein the first plate and the second plate are movable in opposite directions horizontally.

7. The press machine, wherein the first plate includes a first guide as the guide, the second plate includes a second guide as the guide, The laminated core manufacturing apparatus according to claim 6, wherein the first guide and the second guide extend in opposite directions to each other.

8. The laminated core manufacturing apparatus according to any one of claims 1 to 7, wherein the guide includes an adhesion device for adhering between the stacked layers of the group of core pieces from the open side of the guide.

9. The laminated core manufacturing apparatus according to any one of claims 1 to 7, wherein the guide includes a welding device for welding between the stacked layers of the group of core pieces.

10. The laminated core manufacturing apparatus according to any one of claims 1 to 9, comprising a pressing device that presses the group of core pieces on the guide toward the side opposite to the discharging direction of the group of core pieces.

11. The laminated core manufacturing apparatus according to any one of claims 1 to 10, wherein the sheet material supply device supplies a plurality of sheets of sheet material to the press machine in a stacked manner.

12. The laminated core manufacturing apparatus according to any one of claims 1 to 11, wherein the angle formed by both inner side surfaces of the guide is equal to the angle formed by both end portions of the yoke portion of the core piece.

13. The laminated core manufacturing apparatus according to any one of claims 1 to 11, wherein the core piece is discharged from the die in the horizontal direction with respect to the teeth portion, and the guide supports one side surface of the teeth portion of the core piece.

14. The laminated core manufacturing apparatus according to any one of claims 1 to 13, wherein when the angle formed by the guide and the horizontal direction is θ, θ is within 45 degrees from the horizontal direction upward and downward.

15. The laminated core manufacturing apparatus according to claim 14, wherein the guide is inclined downward from the horizontal direction and tan θ < 0.

9.

16. A method of manufacturing a rotating electric machine, wherein an outer peripheral surface of a rotor is opposed to an inner peripheral surface of a stator using a laminated core manufactured using the laminated core manufacturing apparatus according to any one of claims 1 to 15, and the rotor is rotatably supported.

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