Laminate manufacturing apparatus, motor core manufacturing system, and laminate manufacturing method

Abstract

To provide a manufacturing apparatus of a laminate of a motor core in which the degree of freedom of arrangement is improved and a manufacturing system of the motor core.SOLUTION: A manufacturing apparatus 1 of a laminate W2 according to the present invention comprises: a metal mold part 10 which performs punching processing with an upper die and a lower die 12; a base 20 which includes a grounding surface to a floor FL and supports the lower die 12; and a support part 30 which supports a workpiece punched by the upper die and the lower die 12 from below. A lower end part 301 of the support part 30 is arranged on the same level as or on the upper side with respect to the grounding surface of the base 20 and is arranged on the lower side with respect to the upper surface 121 of the lower die 12.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a manufacturing apparatus for a laminate, a manufacturing system for a motor core, and a manufacturing method for a laminate.

Background Art

[0002] Patent Document 1 discloses that in a method for manufacturing a laminate, a lower receiving pad that supports the laminate from below and a support portion that operates the lower receiving pad in the vertical direction are provided.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In recent years, due to the progress of motor core technology and the increasing performance requirements for motor cores, the proportion of the post-punching treatment process, which is performed after the laminate manufacturing process for manufacturing a laminate by punching, in the motor core manufacturing process has been increasing. The length and ideal arrangement of the post-punching treatment process vary depending on the product, and accordingly, the preferable placement location of the laminate manufacturing apparatus also changes more frequently. Therefore, it is necessary to improve the degree of freedom in arrangement even for the apparatus related to the laminate manufacturing process.

[0005] An object of the present invention is to provide a manufacturing apparatus for a laminate of a motor core, a manufacturing system for a motor core, and a manufacturing method for a laminate, in which the degree of freedom in arrangement is improved.

Means for Solving the Problems

[0006] A manufacturing apparatus for a laminate according to one aspect of the present invention includes a die portion that performs punching with an upper die and a lower die, A base having a contact surface with the floor and supporting the lower mold, The system includes a support section that supports the workpiece punched out by the upper die and the lower die from below, The lower end of the support portion is positioned at the same level as or above the contact surface of the base, and below the upper surface of the lower mold.

[0007] A motor core manufacturing system according to one aspect of the present invention is: The manufacturing apparatus for the laminate described above, The laminate has a post-punching processing apparatus, The laminate manufacturing apparatus and the punching post-processing apparatus are installed on the same floor at the same height.

[0008] A method for manufacturing a laminate according to one aspect of the present invention is carried out using the laminate manufacturing apparatus described above.

[0009] A method for manufacturing a laminate according to one aspect of the present invention is: A method for manufacturing a laminate, wherein a workpiece is punched into a predetermined shape by a mold section arranged side by side on a scaffold at a predetermined height from the floor, and the punched-out workpieces are stacked in the lower mold of the mold section to form a laminate, A lamination process in which the laminate is supported from below by a support part disposed between the floor and the lower mold, A discharge step of discharge the laminate from the lower mold, A first transport process involves transporting the discharged laminate via a first transport path located at a higher position than the aforementioned scaffolding, A second transport step involves lowering the stacked material via a second transport path connected to the first transport path, A third transport process involves transporting the lowered stacked material via a third transport path connected to the second transport path and located at a lower position than the scaffolding, Includes. [Effects of the Invention]

[0010] According to the present invention, it is possible to provide a manufacturing apparatus for a motor core laminate, a motor core manufacturing system, and a method for manufacturing a laminate, all of which offer improved flexibility in arrangement. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 is a schematic diagram of a part of the manufacturing apparatus for laminates. [Figure 2] Figure 2 illustrates the lower die and the portion below the lower die, as well as the post-punching processing equipment, as part of a laminate manufacturing apparatus. [Figure 3] Figure 3 illustrates a support structure related to the lamination process. [Figure 4] Figure 4 illustrates a support section related to the first conveying process. [Figure 5] Figure 5 illustrates a manufacturing apparatus and support structure according to a comparative example. [Figure 6] Figure 6 is a view from the direction of arrow VI in Figure 2. [Modes for carrying out the invention]

[0012] Hereinafter, an embodiment of the present invention, a laminate manufacturing apparatus and a motor core manufacturing system, will be described with reference to the drawings. For the sake of explanation, the dimensions of each component shown in these drawings may differ from the actual dimensions of each component.

[0013] Furthermore, for the sake of explanation, we will refer to "up and down direction," "left and right direction," and "front and back direction" as appropriate. Here, "up and down direction" includes the "up" and "down" directions. "Left and right direction" includes the "right" and "left" directions. "Front and back direction" refers to the "forward" and "sideways" directions. In the diagrams described below, the symbol U indicates the upward direction. The symbol D indicates the downward direction. The symbol F indicates the forward direction. The symbol B indicates the backward direction. The symbol L indicates the left direction. The symbol R indicates the right direction. "Horizontal direction" includes the "left and right direction" and the "front and back direction."

[0014] FIG. 1 is a schematic view of a part of a manufacturing apparatus 1 for a laminate W2. FIG. 2 is a view illustrating a lower mold 12 and a portion below the lower mold 12 of the manufacturing apparatus 1 for the laminate W2, and a punching post-treatment apparatus 5. The manufacturing apparatus 1 for the laminate W2 punches a sheet-like workpiece W1 to form a punched member, and laminates the punched members to manufacture the laminate W2. The punched member is an example of a punched workpiece. The coiled workpiece W1 is supplied from an uncoiler 2, and is sent to the manufacturing apparatus 1 by a feeder 4 via a leveler 3 that corrects the curl of the workpiece W1. In the present embodiment, the workpiece W1 is an electromagnetic steel sheet, and the case where the laminate W2 manufactures a motor core that is a core portion in a rotor or a stator of a rotating electric machine is illustrated. The manufacturing apparatus 1 and the punching post-treatment apparatus 5 constitute at least a part of a manufacturing system for the motor core.

[0015] As shown in FIGS. 1 and 2, the manufacturing apparatus 1 includes a die part 10, a base 20, and a support part 30. The die part 10 includes an upper mold 11 and a lower mold 12. The workpiece W1 is sent between the upper mold 11 and the lower mold 12. The upper mold 11 includes a punching punch 111. The upper mold 11 is configured such that the upper mold 11 is displaced in the vertical direction by a driving device (not shown). The lower mold 12 is provided below the upper mold 11. A die hole 12a into which a part of the punching punch 111 can be inserted is formed in the lower mold 12. When the workpiece W1 is between the upper mold 11 and the lower mold 12, the upper mold 11 is displaced downward so that a part of the punching punch 111 is inserted into the die hole 12a, whereby the workpiece W1 is punched to form a punched member. The punched member is conveyed downward through the die hole 12a.

[0016] The lower mold 12 further includes a pusher 12b. The pusher 12b pushes out the laminate W2 manufactured by laminating the punched members toward a first conveyance path P1 described later. Note that the direction in which the pusher 12b pushes out may be different from that of the present embodiment.

[0017] The base 20 comprises legs 21 that contact the floor FL and a mounting table 22 on which the lower mold 12 is placed. The legs 21 have a contact surface that makes contact with the floor FL on which the manufacturing apparatus 1 is placed. The legs 21 support the mounting table 22 from below, and the mounting table 22 supports the lower mold 12 from below.

[0018] The support portion 30 is configured to support the punched-out member from below when the punched-out member is punched out from the workpiece W1. The support portion 30 includes a pad 31 that contacts the punched-out member and supports it from below.

[0019] The support section 30 has a cylinder with a hydraulic chamber inside and a rod that is movable back and forth on the cylinder. The cylinder is fixed to the base 20. A pad 31 is provided at the tip of the rod. As a result, the support section 30 is configured to extend and retract vertically. By changing the length of the rod protruding from the cylinder, the height at which the punched member is supported can be adjusted.

[0020] The support portion 30 is positioned such that its lower end portion 301 is above the ground surface. Furthermore, the support portion 30 is positioned such that its lower end portion 301 is below the upper surface 121 of the lower mold 12. In other words, the support portion 30 is positioned so as to be suspended above the floor FL on which the manufacturing apparatus 1 is placed.

[0021] Next, a method for manufacturing the laminate W2 using the support section 30 will be described. Figure 3 illustrates the support section 30 related to the lamination process. Figure 4 illustrates the support section 30 related to the first transport process.

[0022] As shown in Figure 3, during the lamination process in which punched members are manufactured and the laminate W2 is produced, the laminate W2 is in contact with the die hole 12a and is pressed in the direction of the central axis of the laminate W2. At this time, the support part 30 supports the laminate W2 in a relatively stretched state. When the laminate W2 is pressed in the direction of its central axis, the laminate W2 tends to deform by bending downwards, but the support part 30 supports it from below, which suppresses downward bending of the laminate W2.

[0023] The support section 30 controls the protruding length of the rod by adjusting the hydraulic pressure inside the cylinder, and changes the length of the support section 30 according to the number of stacked punched members. For example, when the number of stacked punched members on the pad 31 is small, the rod moves forward and the support section 30 extends to a relatively long length, and as the number of stacked punched members on the pad 31 increases, the hydraulic pressure is controlled so that the rod moves backward and the support section 30 shortens.

[0024] Once the punching is complete and the laminate W2 is formed, the laminate W2 is discharged downward from the die hole 12a of the lower die 12 (discharge step). The laminate W2 discharged downward from the die hole 12a of the lower die 12 is pushed forward by the pusher 12b. The laminate W2 pushed out by the pusher 12b is further transported forward by the first transport path P1 (see Figure 2) (first transport step). As shown in Figure 2, in this embodiment, the laminate W2 transported forward by the first transport path P1 is sent downward through the second transport path P2 (second transport step). The laminate W2 transported downward through the second transport path P2 is sent to the post-punching processing device 5 through the third transport path P3 (third transport step). In the post-punching processing device 5, permanent magnets may be embedded in the laminate W2, resin material may be molded, welded, measured, inspected, etc. Details of the first transport path P1, the second transport path P2, and the third transport path P3 will be described later.

[0025] Figure 5 illustrates a manufacturing apparatus and support section 30A according to a comparative example. In the manufacturing apparatus according to the comparative example, punched members can be stacked while being supported from below by the support section 30A. However, compared to the manufacturing apparatus of this embodiment, the manufacturing apparatus according to the comparative example differs in that a recess is formed in the floor on which the manufacturing apparatus is placed, and consequently, the lower end portion 301A of the support section 30A is located below the contact surface of the base 20A. In the manufacturing apparatus according to the comparative example, the mold section 10A is located at or below the height of the worker to facilitate mold maintenance.

[0026] In the manufacturing apparatus shown in Figure 5, the mold section 10A was generally configured to be located close to the ground, primarily to facilitate mold maintenance. For this reason, the lower end portion 301A of the support section 30A, which supports the laminated body W2 from below, was located below the floor by forming a recess in the floor.

[0027] However, in recent years, the proportion of post-punching processing equipment in manufacturing systems has increased due to factors such as an increase in processing steps and the implementation of inspection steps after each processing step. Furthermore, if the specifications of the laminated body W2 to be manufactured change, the placement and length of the post-punching processing equipment also change. For this reason, the manufacturing equipment for the laminated body W2 also needs to be configured to be easily rearranged, taking into account its relationship with the post-punching processing equipment. However, as in the comparative example, if there is a recess for arranging the support part 30A, it is difficult to place another device in the place where the manufacturing equipment for the laminated body W2 was located. Also, a new recess needs to be formed where the manufacturing equipment for the laminated body W2 is newly installed. Thus, for the manufacturing equipment for the laminated body W2, there has been a growing desire to improve the flexibility of rearranging the manufacturing equipment rather than prioritizing ease of access to the mold.

[0028] In this embodiment, the lower end portion 301 of the support portion 30 of the manufacturing apparatus 1 is positioned at the same level as or above the contact surface of the base 20. Therefore, when arranging the manufacturing apparatus 1, it is not necessary to form a recess in the floor FL, and the manufacturing apparatus 1 can be placed on a flat floor FL. As a result, when it becomes necessary to rearrange the manufacturing apparatus 1 for the laminate W2, it becomes easier to rearrange another apparatus in the place where the manufacturing apparatus 1 for the laminate W2 was previously located, and the effort required to rearrange the manufacturing apparatus 1 for the laminate W2 to its new location is reduced.

[0029] The motor core manufacturing system 100 of this embodiment comprises a laminate manufacturing apparatus 1 for the laminate W2 and a post-punching processing apparatus 5. The laminate manufacturing apparatus 1 and the post-punching processing apparatus 5 are installed on the same floor FL, which is the same height. Therefore, the effort required for rearranging can be reduced. In particular, this manufacturing system 100 does not require excavation for the installation of the punching apparatus, thus reducing the effort required for reinstalling the punching apparatus. Furthermore, it becomes easier to place another apparatus in the location where the punching apparatus was previously installed, thus improving the overall flexibility of the motor core manufacturing system 100's layout.

[0030] Figure 6 is a view taken from the direction VI in Figure 2. As shown in Figures 2 and 6, the manufacturing apparatus 1 of this embodiment is equipped with a scaffolding 40. In this embodiment, the scaffolding 40 is arranged to surround the manufacturing apparatus 1. As shown in Figure 2, it is desirable that the height of the scaffolding 40 be higher than the ground contact surface of the base 20 and lower than the upper surface 121 of the lower mold.

[0031] In the comparative example shown in Figure 5, a recess was formed in the floor FL to ensure easy access to the mold section 10. However, in the example shown in Figure 6, no recess is formed in the floor FL, so the height from the floor FL to the mold section 10 tends to be high. Therefore, in the example shown in Figure 6, the scaffolding 40 is provided at a height higher than the contact surface of the base 20 and lower than the upper surface 121 of the lower mold, thus maintaining easy access to the mold section 10.

[0032] Furthermore, as shown in Figure 2, in this embodiment, a staircase 41 leading to the upper surface of the scaffolding 40 is provided. This facilitates workers' access to the mold section 10.

[0033] The manufacturing apparatus 1 of this embodiment includes a first transport path P1, a second transport path P2, and a third transport path P3. The first transport path P1 is configured to transport the manufactured laminate W2 horizontally from directly below the lower die 12. The second transport path P2 is configured to lower the laminate W2 transported by the first transport path P1. The third transport path P3 is configured to transport the laminate W2 transported by the second transport path P2 horizontally to the post-punching processing device 5. The first transport path P1 and the second transport path P2, and the second transport path P2 and the third transport path P3 are connected to each other. The first transport path P1 and the third transport path P3 may be, for example, belt conveyors. The second transport path P2 is an example of a lifting section. The second transport path P2 may also be an elevator that transports the laminate W2 downward and then returns to the upper position. Furthermore, the direction in which the first transport path P1 and the third transport path P3 transport the laminate W2 is not limited to the examples of this embodiment.

[0034] The first transport path P1 is provided at approximately the same height as the top surface of the base 20. The second transport path P2, which is the lifting section, is configured to lower the stacked body W2 from approximately the same height as the top surface of the base 20 to a height above the ground surface and below the scaffolding 40. As a result, the third transport path P3 is provided at a height lower than the scaffolding 40, so that the manufacturing apparatus 1 of this embodiment can more easily provide better workability to workers working in the punching post-processing device 5.

[0035] As shown in Figures 2 and 6, the second transport path P2, which is the lifting section, is provided such that a portion of its side is enclosed by the scaffolding 40. In other words, the second transport path P2 is provided so as to penetrate the scaffolding 40.

[0036] A portion of the third transport path P3 is located below the scaffolding 40. "Below the scaffolding 40" refers to the area covered by the scaffolding 40 when viewed from above. For example, in this embodiment, as shown in Figure 6, the stacked body W2 lowered by the second transport path P2 is transported to the left below the scaffolding 40. Subsequently, the stacked body W2 is transported forward. At this time, the third transport path P3 that transports the stacked body W2 to the left and a portion of the third transport path P3 that transports the stacked body W2 forward are covered by the scaffolding 40 when viewed from above.

[0037] In this embodiment, the third transport path P3 is provided such that at least a portion of it passes beneath the scaffolding 40. This makes it possible to save space in the manufacturing apparatus 1, which includes the third transport path P3 and the scaffolding 40.

[0038] As shown in Figures 2 and 6, the manufacturing apparatus 1 of this embodiment has a soundproof wall 50. The soundproof wall 50 is provided to cover at least the sides and top of the mold section 10. As in this embodiment, the soundproof wall 50 may also be provided to cover the sides of the base 20. In addition, a door (not shown) may be provided on one side of the soundproof wall 50 to improve access to the mold section 10.

[0039] An opening is formed in the soundproof wall 50. The opening is sized to allow the laminated body W2, which is being transported from directly below the lower mold 12 by the first transport path P1, to pass through.

[0040] The manufacturing apparatus 1 of this embodiment has a soundproof wall 50, which helps to suppress the impact of noise generated during the manufacturing of the laminated body W2 on the surrounding environment. Furthermore, since openings are formed in the soundproof wall 50, the laminated body W2 can be easily unloaded even with the soundproof wall 50 in place.

[0041] The manufacturing method for the laminate W2 in this embodiment is a method for manufacturing the laminate W2 using the manufacturing apparatus 1 described above. Therefore, the same effects as those of the manufacturing apparatus 1 described above can be obtained.

[0042] The manufacturing method for the laminate W2 of this embodiment includes a lamination process in which the laminate W2 is supported from below by a support portion 30 provided between the floor FL and the lower mold 12. Therefore, it is not necessary to form a recess in the floor FL to provide the support portion 30. As a result, the degree of freedom in arranging the manufacturing apparatus 1 for the laminate W2 is improved.

[0043] Furthermore, the manufacturing method of the laminate W2 in this embodiment includes a second transport step and a third transport step. The second transport step lowers the laminate W2, which is located higher than the scaffolding 40, vertically via a second transport path P2. The third transport step transports the laminate W2 horizontally via a third transport path P3, which is connected to the second transport path P2 and located lower than the scaffolding 40. If the laminate is transported to the post-punching processing device at the height of the first transport path because the support is provided between the floor and the lower die, the laminate will be transported away from the floor, resulting in poor workability in the post-punching processing device. However, the second and third transport steps transport the laminate W2 at a height close to the floor level (FL), improving workability in the post-manufacturing processes of the laminate W2.

[0044] Although embodiments of the present invention have been described above, it goes without saying that the technical scope of the present invention should not be interpreted as being limited by the description of these embodiments. These embodiments are merely examples, and it will be understood by those skilled in the art that various modifications to the embodiments are possible within the scope of the invention described in the claims. The technical scope of the present invention should be determined based on the scope of the invention described in the claims and the scope of its equivalents.

[0045] The configurations listed below also constitute part of the present invention. (1): A die section that performs punching using an upper die and a lower die, A base having a contact surface with the floor and supporting the lower mold, The system includes a support section that supports the workpiece punched out by the upper die and the lower die from below, The lower end of the support portion is positioned at the same level as or above the contact surface of the base, and below the upper surface of the lower mold. A manufacturing apparatus for laminates. (2): A scaffold is provided at a height equal to or higher than the ground contact surface of the base, and lower than the upper surface of the lower mold. (1) Manufacturing apparatus for the laminate. (3): A staircase is provided from the height of the ground surface to the top surface of the scaffolding. (2) Manufacturing apparatus for laminates. (4): The device includes a lifting mechanism that lowers the punched-out workpiece to a height above the ground surface and below the scaffolding. (2) or (3) A manufacturing apparatus for the laminate. (5): The lifting section is surrounded on at least a portion of its sides by the scaffolding. (4) Manufacturing apparatus for laminates. (6): At least a portion of the transport path for transporting the workpiece lowered by the lifting unit is provided below the scaffolding. (4) or (5) Manufacturing apparatus for the laminate. (7): The mold section is provided with soundproof walls that cover at least the top and sides of it. The soundproof wall is provided with an opening through which the laminate can pass. A manufacturing apparatus for any of the laminates described in (1) to (6). (8): A manufacturing apparatus for any of the laminates described in (1) to (7), The laminate has a post-punching processing apparatus, The laminate manufacturing apparatus and the punching post-processing apparatus are installed on the same floor at the same height. Motor core manufacturing system. (9): A method for manufacturing the laminate of the motor core using any of the manufacturing apparatuses (1) to (7). (10): A method for manufacturing a laminate, wherein a workpiece is punched into a predetermined shape by a mold section arranged side by side on a scaffold at a predetermined height from the floor, and the punched-out workpieces are stacked in the lower mold of the mold section to form a laminate, A lamination process in which the laminate is supported from below by a support part disposed between the floor and the lower mold, A discharge step of discharge the laminate from the lower mold, A first transport process involves transporting the discharged laminate via a first transport path located at a higher position than the aforementioned scaffolding, A second transport step involves lowering the stacked material via a second transport path connected to the first transport path, A third transport process involves transporting the lowered stacked material via a third transport path connected to the second transport path and located at a lower position than the scaffolding, A method for manufacturing a laminate containing a laminate. [Explanation of Symbols]

[0046] 1 Manufacturing equipment 2 Ankoira 3 Level 4. Feed device 5. Post-punching processing equipment 10,10A Mold section 11 Upper mold 12 Lower mold 12a Die hole 12b Pusher 20,20A base 21 Legs 22 Mounting platform 30,30A support part 31 pads 40 scaffolding 41 Stairs 50 Soundproof wall 100 Manufacturing Systems 111 Punch 121 Top surface 301,301A Lower end FL floor P1 First transport route P2 Second transport route P3 Third transport route W1 Work W2 Laminate

Claims

1. A die section that performs punching using an upper die and a lower die, A base having a contact surface with the floor and supporting the lower mold, The system includes a support section that supports the workpiece punched out by the upper die and the lower die from below, The lower end of the support portion is positioned at the same level as or above the contact surface of the base, and below the upper surface of the lower mold. A scaffold is provided at a height equal to or higher than the ground contact surface of the base, and lower than the upper surface of the lower mold. A manufacturing apparatus for laminates.

2. A staircase is provided from the height of the ground surface to the top surface of the scaffolding. The apparatus for manufacturing a laminate according to claim 1.

3. The device includes a lifting mechanism that lowers the punched-out workpiece to a height above the ground surface and below the scaffolding. The apparatus for manufacturing a laminate according to claim 1.

4. The lifting section is surrounded on at least a portion of its sides by the scaffolding. The apparatus for manufacturing a laminate according to claim 3.

5. At least a portion of the transport path for transporting the workpiece lowered by the lifting unit is provided below the scaffolding. The apparatus for manufacturing a laminate according to claim 3.

6. The mold section is provided with soundproof walls that cover at least the top and sides of it. The soundproof wall is provided with an opening through which the laminate can pass. The apparatus for manufacturing a laminate according to claim 1.

7. A laminate manufacturing apparatus according to any one of claims 1 to 6, The laminate is equipped with a post-punching processing device that performs post-punching processing on the laminate, The laminate manufacturing apparatus and the punching post-processing apparatus are installed on a common floor at the same height. Motor core manufacturing system.

8. A method for manufacturing the laminate using the manufacturing apparatus described in claim 1.

9. A method for manufacturing a laminate, wherein a workpiece is punched into a predetermined shape by a mold section arranged side by side on a scaffold at a predetermined height from the floor, and the punched-out workpieces are stacked in the lower mold of the mold section to form a laminate, A lamination process in which the laminate is supported from below by a support part disposed between the floor and the lower mold, A discharge step of discharge the laminate from the lower mold, A first transport process involves transporting the discharged laminate via a first transport path located at a higher position than the aforementioned scaffolding, A second transport step involves lowering the stacked material via a second transport path connected to the first transport path, A third transport process involves transporting the lowered stacked material via a third transport path connected to the second transport path and located at a lower position than the scaffolding, A method for manufacturing a laminate containing a laminate.

Images