Laminated iron core production device and laminated iron core production method

Abstract

Prior to punching out iron core pieces from a workpiece (80), a coupling means is attached to to-be-machined portions of the workpiece (80) that correspond to the iron core pieces, and the iron core pieces that were punched out from the workpiece (80) and laminated are integrally formed by the coupling means to produce a laminated iron core. Meanwhile, the workpiece (80) is supported by a lifter part (27) that has relief sections (27a) at portions thereof overlapping the coupling-means attached position of the workpiece (80), and while the workpiece (80) to which the coupling means has been attached is transported, the coupling means attached to the workpiece (80) moves on the relief sections (27a) of the lifter part (27). Thus, while the workpiece (80) is transported, the lifter part (27) can support the parts of the workpiece without contacting the coupling means, thereby avoiding an adverse effect that could occur if production device components contact the workpiece or the coupling means.

Description

Laminated iron core manufacturing device and laminated iron core manufacturing method

[0001] The present disclosure relates to a manufacturing apparatus for a laminated core and a manufacturing method applied thereto.

[0002] Laminated cores are generally used as the cores in which coils and permanent magnets are arranged in the stators or rotors of rotating electrical machines such as electric motors and generators. Laminated cores are manufactured by laminating core pieces obtained by pressing a workpiece.

[0003] When punching out complex shapes such as iron core pieces from a metal workpiece by press working, a commonly used method is so-called progressive processing, in which a strip of workpiece is fed while multiple punching steps are carried out using a press with a die. The iron core pieces finally punched out from the workpiece are then stacked, and the stacked iron core pieces are integrated by caulking, adhesive, etc. to form a laminated core.

[0004] When stacked core pieces are integrated by bonding, an adhesive applicator installed in a mold applies adhesive to the processing target portions of the workpiece corresponding to the core pieces before punching out the core pieces. The adhesive-coated core pieces are then punched out and stacked, thereby bonding the core pieces together. An example of a laminated core manufacturing device that employs this type of conventional bonding integration is disclosed in Japanese Patent No. 6,843,887.

[0005] Japanese Patent No. 6843887

[0006] As shown in the above-mentioned patent document, conventional laminated cores are manufactured by applying adhesive to multiple locations in the areas to be processed of the workpiece, punching out these areas to be processed, and stacking the resulting core pieces and bonding them together.

[0007] In the manufacturing apparatus described in Japanese Patent No. 6843887, the workpiece (hoop material) is supported at both widthwise ends by lifter pins during feeding, and is lifted up so that it is transported away from the upper surface of the die plate supporting the die.

[0008] On the other hand, in recent years, as workpieces have become thinner, they have become more susceptible to deformation. As a result, when supporting both widthwise ends of the workpiece to lift it, the center of the workpiece sags, increasing the risk of the workpiece being dragged against the die plate on the upper surface of the lower die.

[0009] If the workpiece is dragged against the die plate on the upper surface of the lower die during transportation, the adhesive applied to the workpiece may adhere to the die plate. In such a situation, the amount of adhesive adhering to the workpiece may be insufficient, which may result in the iron core pieces punched out of the workpiece not being properly laminated together. In addition, adhesive may adhere and remain on the surface of the die plate, adversely affecting the transportation and processing of the workpiece.

[0010] The present disclosure aims to provide a laminated iron core manufacturing device and a laminated iron core manufacturing method in which a workpiece to which a connecting means such as an adhesive has been applied is supported by a lifter section that contacts the portion of the workpiece to which the connecting means has not been applied, thereby allowing the workpiece to be processed and transported.

[0011] The laminated core manufacturing apparatus of the present disclosure presses intermittently transported strip-shaped workpiece material to obtain core pieces of a predetermined shape, and stacks multiple core pieces to manufacture a laminated core, and is equipped with an attachment section that attaches multiple connecting means to the processing target portions of the workpiece material that correspond to the core pieces, for connecting the stacked core pieces together, a punching section that punches out the processing target portions to which the connecting means have been attached from the workpiece material to form the core pieces, and a lifter section consisting of one or more plate-shaped bodies that supports from below the workpiece material being transported from at least the attachment section to the punching section, and the lifter section has multiple recesses that overlap with the positions of the connecting means in the transported workpiece material, which are provided continuously in the transport direction of the workpiece material, and supports the workpiece material by contacting the positions of the connecting means absent in the workpiece material at points other than the recesses.

[0012] According to the present disclosure, before punching core pieces from the workpiece, connecting means are applied to the workpiece's processing target portion corresponding to the core pieces, and the core pieces punched from the workpiece and laminated are integrated using the connecting means, thereby manufacturing a laminated core. Meanwhile, the workpiece is supported by a lifter section having a recessed portion in the area where the connecting means is applied to the workpiece, and while the workpiece with the connecting means is being transported, the connecting means applied to the workpiece moves along the recessed portion of the lifter section. This allows the lifter section to support each part of the workpiece without contacting the connecting means, even while the workpiece is being transported, thereby suppressing deformation of the workpiece. Additionally, adverse effects caused by contact between each part of the manufacturing equipment and the workpiece or the connecting means can be avoided, improving the efficiency of laminated core manufacturing.

[0013] FIG. 1 is a diagram illustrating a workpiece transport state in a laminated core manufacturing apparatus according to a first embodiment. FIG. 2A is a schematic plan view of a lower die in the laminated core manufacturing apparatus according to the first embodiment. FIG. 2B is a diagram illustrating a workpiece punching state by the laminated core manufacturing apparatus according to the first embodiment. FIG. 3A is a diagram illustrating a position of a lifter section in the laminated core manufacturing apparatus according to the first embodiment when a workpiece is transported. FIG. 3B is a diagram illustrating a maximum lowered state of the lifter section in the laminated core manufacturing apparatus according to the first embodiment. FIG. 3B is a diagram illustrating a maximum lowered state of the upper die in the laminated core manufacturing apparatus according to the first embodiment. A plan view of a lifter section in a laminated core manufacturing apparatus according to a second embodiment. A diagram illustrating the positional relationship between an adhesive application section, an adhesive application portion of a workpiece, and the lifter section in a laminated core manufacturing apparatus according to the second embodiment.

[0014] First Embodiment A laminated core manufacturing apparatus according to a first embodiment will be described below with reference to Figures 1 to 4. In this embodiment, an example of an apparatus will be described in which core pieces of a predetermined shape are obtained by press working, and then a plurality of the core pieces are laminated and bonded together to manufacture a laminated core for a stator of a rotating electric machine.

[0015] The laminated core manufacturing apparatus 1 is configured to perform progressive press working on a workpiece 80, which is a strip of magnetic metal material, to obtain core pieces 81 of a predetermined shape, and to laminate the core pieces 81 to manufacture a laminated core 85. The laminated core manufacturing apparatus 1 includes an adhesive application unit 25 as an application unit, a punching unit 30, and a lifter unit 27.

[0016] The laminated core manufacturing apparatus 1 performs punching in multiple stages on the intermittently transported workpiece 80 by progressive processing using an upper die 10 and a lower die 20. The laminated core manufacturing apparatus 1 is also configured to have a mechanism for forming the shapes of each part of the core piece 81 in the processing target portion of the workpiece 80 that corresponds to the core piece 81.

[0017] The laminated core manufacturing apparatus 1 also has an adhesive application unit 25 as an application unit. The adhesive application unit 25 applies a plurality of connecting means for connecting the laminated core pieces to each other to the processing target portion of the workpiece 80 at a predetermined intermediate stage of the progressive processing.

[0018] Furthermore, the laminated core manufacturing apparatus 1 has a punching section 30. In the final stage of progressive processing, the punching section 30 punches out the processing target portion, to which the connecting means has been applied in the adhesive application section 21, from the workpiece 80 to manufacture the core pieces 81. In addition, the laminated core manufacturing apparatus 1 has a lifter section 27. The lifter section 27 supports the workpiece 80 from below as it is transported from the adhesive application section 25, which serves as an application section, to the punching section 30.

[0019] The basic configuration of the laminated core manufacturing apparatus 1, which performs progressive processing using the upper die 10 and lower die 20, is similar to that of a known press processing apparatus used in progressive processing press processing, and detailed description thereof will be omitted. In particular, the mechanisms of the laminated core manufacturing apparatus 1 that perform punching in multiple stages upstream of the adhesive application section 25 are similar to those of known devices used in progressive processing press processing, and description thereof will be omitted. The configuration for supporting the workpiece 80 with the lifter section 27 in the laminated core manufacturing apparatus 1 will be specifically described below.

[0020] The laminated core manufacturing method applied to the laminated core manufacturing apparatus 1 according to this embodiment includes at least an adhesive application step as an application step, and a punching step. The adhesive application step is a step in which the adhesive application unit 25 applies adhesive 40 to multiple locations on the processing target portion of the workpiece 80. The punching step is a step in which the punching unit 30 punches out the processing target portion of the workpiece 80 to obtain core pieces 81.

[0021] The laminated core 85 manufactured by the laminated core manufacturing apparatus 1 according to this embodiment is formed by stacking a plurality of core pieces 81 made of a magnetic metal material. The laminated core 85 includes an annular yoke portion and a plurality of teeth that protrude from the inner periphery of the yoke portion and are arranged radially. The laminated core 85 is used as a key part of the stator of a rotating electrical machine (electric motor or generator). The laminated core 85 has a known structure, and detailed description thereof will be omitted.

[0022] The laminated core manufacturing apparatus 1 performs progressive processing on a workpiece 80 that is intermittently transported by a known delivery device 60, using an upper die 10 that is arranged above the transport path of the workpiece 80 and a lower die 20 that is arranged below the transport path of the workpiece 80. Specifically, the laminated core manufacturing apparatus 1 moves the upper die 10 up and down relative to the lower die 20 for the intermittently transported workpiece 80, and punches out the target processing portion of the workpiece 80 multiple times with the punch of the upper die 10 and the die of the lower die 20.

[0023] The upper die 10 includes punches 11, 12, 13, and 14 for punching, a stripper 15 for suppressing unnecessary movement of the workpiece 80, and a punch holder 16 for supporting these punches 11, 12, 13, and 14 and the stripper 15. The punch, stripper, and punch holder mechanisms included in the upper die 10 have the same configuration as the upper die in a press working device that performs punching by known progressive working.

[0024] The punches 11, 12, 13, and 14 are provided at positions corresponding to the dies formed on the lower mold 20. The punches 11, 12, 13, and 14 are configured to punch the workpiece 80 into a predetermined shape by descending toward their respective dies. The punches 11, 12, 13, and 14 are attached to a punch holder 16 and supported in a suspended state. The configuration of the punches 11, 12, 13, and 14 is similar to that used in a press processing device that punches out core pieces that form laminated cores using a known progressive process, and detailed description thereof will be omitted. Of the punches, the fourth punch 14 forms part of a punching processing section 30 that punches out the portion to be processed of the workpiece 80 to form the core piece 81.

[0025] The stripper 15 presses and holds the workpiece 80 against each die of the lower mold 20 from above when the punches 11, 12, 13, and 14 punch out the workpiece 80. The stripper 15 also plays a role in holding back the workpiece 80 that tends to rise as the punches 11, 12, 13, and 14 that have bitten into the workpiece 80 try to return to their original positions after punching, and in moving the workpiece 80 away from the punches 11, 12, 13, and 14.

[0026] The stripper 15 is supported in a state where it is suspended from the punch holder 16 and is movable up and down relative to the punch holder 16. The lower parts of the punches 11, 12, 13, and 14 are inserted into the stripper 15, and before and after punching, the punches 11, 12, 13, and 14 each move up and down relative to the stripper 15 in contact with the workpiece 80.

[0027] The stripper 15 is provided with a downwardly protruding pressing portion 19 which is movable vertically relative to the die on the lower mold 20 side together with the stripper 15. The pressing portion 19 also forms a part of the punching section 30.

[0028] The pressing portion 19 contacts the lifter portion 27 and relatively presses down the lifter portion 27 in synchronization with the timing at which the punching portion 30 punches out the processing target portion from the workpiece 80. This allows the lower surface of the workpiece 80 supported by the lifter portion 27 to come into contact with the upper end of the die.

[0029] The configuration of the stripper 15, except for the pressing portion 19, is the same as that used in a known press processing device for performing punching, and detailed description thereof will be omitted.

[0030] The punch holder 16 is a known plate-like part that supports the plurality of punches 11, 12, 13, 14 and the stripper 15 in a suspended state from above.

[0031] The lower die 20 includes punching dies 21, 22, 23, and 24, an adhesive application section 25, a die shoe 26 that supports the dies 21, 22, 23, and 24 and the adhesive application section 25, and a lifter section 27 that supports the workpiece 80.

[0032] The dies 21, 22, 23, and 24 are disposed above the die shoe 26 at predetermined intervals in the conveying direction of the workpiece 80. Each of the dies 21, 22, 23, and 24 has a die hole 21a, 22a, 23a, and 24a formed therein as a hole penetrating in the vertical direction, through which the corresponding punch 11, 12, 13, and 14 on the upper die 10 side can be inserted and removed. Each of the dies 21, 22, 23, and 24 is a known die that punches the workpiece 80 in pairs with the corresponding punch 11, 12, 13, and 14, and detailed description thereof will be omitted.

[0033] Of the dies, the fourth die 24, together with the corresponding fourth punch 14, constitutes a main part of the punching section 30. The fourth punch 14 and the fourth die 24 punch out the portion to be processed of the workpiece 80 after adhesive has been applied by the adhesive application section 25, and form iron core pieces 81 to which the adhesive has adhered. In the die hole 24a of the fourth die 24, the iron core pieces 81 punched out from the workpiece 80 are stacked on top of the iron core pieces 81 that were punched out previously, resulting in a stack of multiple iron core pieces 81.

[0034] The adhesive applicator 25 is disposed between the third die 23 and the fourth die 24 above the die shoe 26. The adhesive applicator 25 applies adhesive as a connecting means to multiple locations on the workpiece 80 to be processed from below.

[0035] The adhesive applicator 25 has a plurality of outlets 25a for discharging adhesive, which are arranged so that the adhesive can be applied to a plurality of predetermined locations on the underside of the workpiece 80. On the other hand, the adhesive applicator 25 is configured so that the adhesive is not applied to some areas of the workpiece 80 by setting the arrangement of the outlets 25a and the amount of adhesive to be applied. The configuration for supplying and applying adhesive in the adhesive applicator 25 is similar to an adhesive application mechanism used in known press working devices, which has a process of applying adhesive to a plurality of locations on the workpiece midway through progressive working, and a detailed description thereof will be omitted.

[0036] The die shoe 26 is a platform-shaped component that supports the dies 21, 22, 23, and 24, the adhesive application section 25, and the lifter section 27. The dies 21, 22, and 23 are supported by the die shoe 26 while being fitted into a die plate 28 provided above the die shoe 26. The die shoe 26 is connected to a known guide mechanism (not shown) to allow the punch holder 16 of the upper die 10 to move in the vertical direction and to restrict movement in directions other than the vertical direction.

[0037] A plurality of discharge holes 26a, 26b, 26c, and 26d are formed inside the die shoe 26. Of these, the discharge holes 26a, 26b, and 26c communicate with the die holes 21a, 22a, and 23a of the dies 21, 22, and 23, and are formed to discharge material pieces (waste material) punched out from the workpiece 80. In addition, the discharge hole 26d of the die shoe 26, which communicates with the die hole 24a of the fourth die 24, is formed to send out the plurality of punched and stacked core pieces 81 to the outside in the final state of the laminated core 85.

[0038] The laminated core pieces 81 are bonded to other core pieces with a coated adhesive to form an integrated laminated core 85. The laminated core 85 is transported through the discharge hole 26d by a known transport device such as a belt conveyor to a device for the next process (for example, a heating device, a magnet insertion device, a resin injection device, etc.).

[0039] The lifter section 27 is a plate-like body that is movable up and down from the end of the adhesive application section 25 on the upper side of the die shoe 26 to the periphery of the fourth die 24. The lifter section 27 is configured to support the vicinity of the adhesive on the conveyed workpiece 80 with the upper surface of the plate-like body.

[0040] The lifter section 27 is configured to push up the workpiece 80 from below while the workpiece 80 is being transported. As a result, the lower surface of the workpiece 80 and the adhesive as a connecting means are positioned above the upper end of the die 24. This prevents the workpiece 80 and the adhesive from coming into contact with the die 24.

[0041] The lifter section 27 is provided with a groove that is continuous in the conveyance direction of the workpiece 80 as a relief section 27a that corresponds to the application position of the adhesive on the workpiece 80. The portion of the lifter section 27 without the relief section 27a contacts the position of the workpiece 80 near the adhesive, i.e., the position where the adhesive is not applied, and supports the workpiece 80.

[0042] The lifter section 27 is attached to the die shoe 26 so as to be movable up and down within a predetermined range, and is configured to be biased upward by a predetermined elastic member. When the lifter section 27 is not subjected to external force, such as when the workpiece 80 is being transported, the lifter section 27 is configured to push up the workpiece 80 and separate it from the die 24 by the bias of the elastic member.

[0043] On the other hand, during punching, the lifter portion 27 is forcibly pressed down by the presser portion 19 that forms part of the punching processing section 30. As a result, the lower surface of the workpiece 80 supported by the lifter portion 27 comes into contact with the upper end of the die 24.

[0044] The position where the lifter portion 27 is pressed from above by the pressing portion 19 is set to a location that does not overlap with the workpiece 80 at the timing of punching and is exposed upward, for example, a location corresponding to a through-hole provided in the workpiece 80 or a location outside the end in the width direction of the workpiece 80. The through-hole provided in the workpiece 80 is a location that was punched in a process before the adhesive application portion 25.

[0045] The lifter portion 27 is not limited to a single continuous plate-like body, but may have a structure in which a plurality of small plate-like bodies are combined.

[0046] The relief portion 27a of the lifter portion 27 is not limited to a groove, as long as it can contain the adhesive applied to the workpiece 80 within the range of the relief portion 27a while the workpiece 80 is being transported, and allow the workpiece 80 to be moved on the lifter portion 27 without contact between the lifter portion 27 and the adhesive. For example, the relief portion may be a recess, notch, or hole that continues in the direction of transport of the workpiece in the lifter portion. Furthermore, if the lifter portion is configured by combining multiple plate-like bodies, the relief portion may be a gap between the plate-like bodies.

[0047] The lower die 20 may be provided with another lifter section upstream of the adhesive application section 25. The other lifter section may have a mechanism similar to that used in known progressive press working devices, so long as it prevents the lower surface of the workpiece 80 from contacting the dies 21, 22, and 23 when the workpiece 80 is being transported. In this case, it goes without saying that the other lifter section descends during punching to allow the lower surface of the workpiece to come into contact with the dies.

[0048] Next, the manufacturing process of the laminated core 85 by the laminated core manufacturing apparatus 1 according to this embodiment will be described. The laminated core manufacturing apparatus 1 performs progressive processing on a strip-shaped workpiece 80 that is intermittently transported by the delivery device 60. In progressive processing, the workpiece 80 is punched out to correspond to the shape of each part of the core piece 81 other than the outer periphery, and adhesive is applied to the workpiece 80 by the adhesive application unit 25. In progressive processing, the core piece 8 is finally punched out and separated from the workpiece 80.

[0049] A continuous strip of workpiece material 80 is intermittently transported by a delivery device 60 and fed into between the upper die 10 and the lower die 20 of the laminated core manufacturing apparatus 1. The workpiece material 80 is transported by a preset feed amount, and when a predetermined portion of the workpiece material 80 reaches between the first punch 11 and the die 21, the transport is temporarily stopped and the upper die 10 is lowered so as to approach the lower die 20.

[0050] The stripper 15 of the upper die 10 gradually approaches the workpiece 80. The stripper 15 comes into contact with the workpiece 80 and presses the workpiece 80 against the die 21. As a result, the workpiece 80 is sandwiched between the stripper 15 and the die 21. The stripper 15, which is pressing down on the workpiece 80 from above, does not move further downward, while the punch holder 16 and punch 11 move further downward, and the tip of the punch 11 reaches the die 21 through the insertion portion of the stripper 15. As a result, a portion of the workpiece 80 is punched out by the punch 11 and the die 21, and this punching forms a through-hole in the workpiece 80 (see FIG. 2B ).

[0051] After punching, the punch holder 16 and punch 11 move upward. When the punch 11 separates from the workpiece 80, the stripper 15 also rises and separates from the workpiece 80. As each part of the upper die 10 subsequently returns to its original position, the transport of the workpiece 80 is resumed at an appropriate timing.

[0052] When the portion of the workpiece 80 being conveyed to be processed reaches the gap between the second punch 12 and the die 22, conveyance is temporarily stopped, as in the case of the first punch 11 and the die 21. The upper die 10 is lowered, and a portion of the workpiece 80 is punched out by the punch 12 and the die 22. This punching forms a new through-hole in the workpiece 80 (see FIG. 2B ). After punching, conveyance of the workpiece 80 is resumed as each part of the upper die 10 returns to its original position.

[0053] When the portion of the workpiece 80 being conveyed to be processed reaches the gap between the third punch 13 and the die 23, conveyance is temporarily stopped, as in the case of the first punch 11 and the die 21. The upper die 10 is lowered, and a portion of the workpiece 80 is punched out by the punch 13 and the die 23. This punching forms a further through hole in the workpiece 80 (see FIG. 2B ). After punching, conveyance of the workpiece 80 is resumed as each portion of the upper die 10 returns to its original position.

[0054] Each punching operation by the first punch 11 and die 21, the second punch 12 and die 22, and the third punch 13 and die 23 is similar to punching by progressive processing in a known press processing device, so further detailed explanation will be omitted.

[0055] The punching by the first punch 11 and die 21 is performed, for example, to provide a pilot hole 83 in the workpiece 80 (see FIG. 2B). The pilot hole 83 is a hole provided and used in known progressive machining, for inserting a positioning pin to prevent the workpiece from moving when punching by the subsequent punches and dies.

[0056] Furthermore, punching using the second punch 12 and die 22 is performed, for example, to form a hole in the workpiece 80 that corresponds to the shape of a portion of the core piece 81 (see FIG. 2B). Furthermore, punching using the third punch 13 and die 23 is performed, for example, to punch out the center of the portion to be processed in the workpiece 80, so that the shapes of the portions of the workpiece 80 other than the outer periphery of the core piece 81 appear (see FIG. 2B).

[0057] The waste material produced by punching out with each punch and die is discharged to the outside through each die hole 21a, 22a, 23a and each discharge hole 26a, 26b, 26c of the die shoe 26 that communicates with these.

[0058] When the portion to be processed of the workpiece 80 being conveyed after being punched by the third punch 13 and die 23 reaches the adhesive application section 25, the conveyance is temporarily stopped. Then, the upper die 10 moves downward so as to approach the lower die 20. The stripper 15 of the upper die 10 gradually approaches the workpiece 80. The stripper 15 comes into contact with the workpiece 80 and presses the workpiece 80 against the adhesive application section 25. The workpiece 80 is now sandwiched between the stripper 15 and the adhesive application section 25.

[0059] When the workpiece 80 is in contact with the adhesive applicator 25, liquid adhesive is supplied to each outlet 25a of the adhesive applicator 25. As a result, adhesive is applied to a plurality of predetermined locations facing each outlet 25a on the underside of the portion to be processed of the workpiece 80. On the other hand, adhesive is not applied to the underside of the workpiece 80 other than the locations facing the outlets 25a.

[0060] After the adhesive is applied, the stripper 15 rises together with the other parts of the upper die 10, such as the punch holder 16, and moves away from the workpiece 80. As each part of the upper die 10 subsequently returns to its original position, the conveyance of the workpiece 80 is resumed at an appropriate timing.

[0061] Note that adhesive is not supplied to each outlet 25a of the adhesive application unit 25 to the processing target portion of the workpiece 80 corresponding to the core pieces 81 that form the bottom layer of the laminated core 85. Therefore, adhesive is not applied to the core pieces 81 that form the bottom layer of the laminated core 85. This makes it possible to prevent the adhesive adhering to the underside of the bottom layer core piece 81 obtained by punching in the punching processing unit 30 from adversely affecting the various parts of the mechanism that stacks the core pieces.

[0062] Similarly, as another mechanism for preventing adhesive from being applied to the portion of the workpiece to be processed as needed, a mechanism may be adopted in which the adhesive application section moves downward and retreats to avoid contact with the workpiece at times when adhesive should not be applied.

[0063] The portion of the workpiece 80 to be processed, to which adhesive has been applied, is supported by the lifter portion 27 while it is being transported from the adhesive application portion 25 to the portion between the fourth punch 14 and the die 24 that constitutes the punching portion 30. When the portion of the workpiece 80 to be processed is supported by the lifter portion 27, the lifter portion 27 is configured to support the portion of the workpiece 80 to be processed by bringing the upper surface of the plate-like body that constitutes the lifter portion 27 into contact with each position of the workpiece 80 that is in the vicinity of the applied adhesive. In addition, because the portion of the underside of the workpiece 80 to which adhesive has been applied passes through the groove that is the relief portion 27a of the lifter portion 27, the adhesive is less likely to adhere to the lifter portion 27.

[0064] Furthermore, when the workpiece 80 is transported, the stripper 15 is located above the workpiece 80, and the presser portion 19 is also located away from the lifter portion 27. Therefore, the lifter portion 27, to which no external force is applied, supports the workpiece 80 so that it is located above the upper end of the die 24. Therefore, the adhesive applied to the lower surface of the workpiece 80 is less likely to come into contact with the die.

[0065] When the portion to be processed of the conveyed workpiece 80 reaches the gap between the fourth punch 14 and the die 24, which constitutes the punching section 30, the conveyance is temporarily stopped. The stripper 15 is positioned above the workpiece 80, and the presser section 19 is also away from the lifter section 27. Therefore, the lifter section 27, which is not receiving a pressing force from above, supports the workpiece 80 above the upper end of the die 24.

[0066] With the conveyance temporarily stopped, the upper die 10 descends so as to approach the lower die 20. The stripper 15 of the upper die 10 gradually approaches the workpiece 80 and comes into contact with the workpiece 80. The descending stripper 15 then presses the workpiece 80 while pressing the lifter portion 27 downward with the integral presser portion 19. The stripper 15 lowers the workpiece 80 supported by the lifter portion 27 until it comes into contact with the die 24. As a result, the workpiece 80 is sandwiched between the stripper 15 and the die 24 (see FIG. 3B ).

[0067] Not only does the stripper 15 press down the lifter portion 27 via the workpiece 80, but the presser portion 19 also directly presses down the lifter portion 27 at a location where there is no workpiece 80. This makes it possible to obtain a state in which the force pressing down the lifter portion 27 is applied evenly.

[0068] It should be noted that the present invention is not limited to a configuration in which the pressing portion 19 directly presses down the lifter portion 27. As long as the lifter portion can be pressed down appropriately, a configuration in which a stripper without a pressing portion presses the workpiece to press down the lifter portion via the workpiece may also be used.

[0069] With the workpiece 80 sandwiched between it and the die 24 and the stripper 15 now immobile, the punch holder 26 and punch 14 move further downward, and the tip of the punch 14 reaches the die 24 after passing through the insertion portion of the stripper 15. As a result, the portion to be processed of the workpiece 80 is punched out by the punch 14 and die 24 that form the punching processing portion 30. This punching separates the portion to be processed from the workpiece 80 and turns it into core pieces 81, while a hole corresponding to the outer edge shape of the core piece 81 remains in the workpiece 80 (see FIG. 2B ).

[0070] The multiple core pieces 81 obtained by punching with the punch 14 and die 24 that form the punching processing section 30 are stacked in the die hole 24a. The core pieces 81 are temporarily held in a stacked state in the die hole 24a. The stacked core pieces 81 move downward each time a new core piece 81 is punched out and stacked. The core pieces 81 may be stacked while making adjustments such as rotating the stack as necessary.

[0071] The multiple core pieces 81 are bonded together during the lamination process. When the number of stacked core pieces 81 (lamination thickness) reaches a specified value, the stacked and integrated core pieces 81, i.e., a laminated core 85, is discharged outside the device through the discharge hole 26d of the die shoe 26. The laminated core 85 is then discharged to the next process by a discharge device (not shown).

[0072] In the laminated core manufacturing apparatus 1 according to this embodiment, before punching core pieces from the workpiece 80, adhesive is applied to the processing target portion of the workpiece 80, and the laminated core pieces 81 punched from the workpiece 80 are integrated by adhesive, thereby manufacturing a laminated core 85. Meanwhile, the workpiece 80 is supported by a lifter portion 27 having a recess 27a in the portion of the workpiece 80 that overlaps with the adhesive application position. During transport of the workpiece 80, the adhesive applied to the workpiece 80 moves along the recess 27a of the lifter portion 27. As a result, the lifter portion 27 supports each portion of the workpiece 80 without coming into contact with the adhesive, even during transport of the workpiece 80, thereby suppressing deformation of the workpiece 80. Additionally, adverse effects due to contact between each portion of the apparatus and the workpiece 80 or adhesive can be avoided, improving the efficiency of laminated core manufacturing.

[0073] The laminated core manufacturing apparatus 1 according to this embodiment is provided with an adhesive applicator 25 as an applicator that applies a connecting means. The adhesive applicator 25 is configured to apply adhesive to connect the workpieces 80 together. However, the means for connecting the workpieces 80 together is not limited to this. For example, a caulking portion that is concave on the top surface of the workpieces and convex on the bottom surface may be formed as a connecting means for connecting the workpieces together. In this case, the applicator that applies the connecting means is a mechanism that forms a caulking portion by pressing the workpieces together, instead of an adhesive applicator.

[0074] The lifter section supports the workpiece so that the crimped portion, which is convex on the underside of the workpiece, does not come into contact with the die, and the relief section also prevents the crimped portion from coming into contact with the lifter section itself. In this case, the lifter section also supports the workpiece with its upper surface in contact with a position on the workpiece near the crimped portion, i.e., a position where there is no crimped portion. The core pieces punched out by the punching section are stacked with other core pieces and integrated by a crimping process that connects the overlapping crimped portions by applying a vertical pressing force, ultimately forming a laminated core.

[0075] When a crimping portion is used as the connecting means in this way, as with adhesive, no crimping portion is formed as a connecting means at the application portion in the processing target portion of the workpiece corresponding to the core piece arranged in the bottom layer of the laminated core. For example, instead of forming a normal crimping portion that is convex on the underside of the processing target portion of the workpiece, the application portion may form a hole on the upper side of the processing target portion. The hole is formed so that the core piece can be connected and integrated with the crimping portion of another core piece by crimping.

[0076] The connecting means may be a heat-curing adhesive or caulking, which does not easily connect the core pieces to other overlapping core pieces. In this case, after punching, the stacked core pieces are not integrated, but are discharged from the laminated core manufacturing apparatus in a predetermined number of stacks while remaining separable. The predetermined number of stacked core pieces may be processed outside the apparatus to be integrated into a laminated core, and then sent to the next process.

[0077] Second Embodiment In the laminated core manufacturing apparatus according to the first embodiment, the portions to be processed that correspond to the core pieces in the strip-shaped workpiece 80 used are set to be aligned in a row in the conveyance direction of the workpiece 80. Therefore, the punch and die sets, adhesive application unit 25, and lifter unit 27 are also arranged in a row. However, this is not limited to this, and for example, the portions to be processed in the workpiece 80 may be arranged in multiple rows, such as two rows, in the conveyance direction of the workpiece 80. Accordingly, the laminated core manufacturing apparatus may also be configured to accommodate multiple rows of portions to be processed.

[0078] In this case, too, the adhesive applicator 45 is arranged for each row of processing target portions aligned in the conveying direction of the workpiece 80. Relief portions 47a are formed in the lifter portion 47 corresponding to the multiple adhesive application positions on the workpiece by the adhesive applicator 45 (see FIGS. 5 and 6 ). As a result, as in the first embodiment, the upper surface of the lifter portion 47 contacts the workpiece 80 at a position near the adhesive during conveyance of the workpiece 80. Therefore, the lifter portion 47 supports each portion of the workpiece 80 without contacting the adhesive, thereby suppressing deformation of the workpiece 80. Additionally, adverse effects due to contact between each device component, including the die 44 and the lifter portion 47, and the workpiece 80 or adhesive can be avoided, thereby improving the efficiency of laminated core manufacturing.

[0079] The present disclosure has been described above based on the embodiments. The present embodiment is an example of the present disclosure, and is not limited to the above-described embodiment, and can be freely modified, improved, etc. as appropriate. In addition, the material, shape, dimensions, numerical values, form, number, placement location, etc. of each component in the above-described embodiment are arbitrary and not limited as long as the present disclosure can be achieved.

[0080] This application appropriately incorporates the contents disclosed in Japanese Patent Application No. 2023-133167 filed on July 27, 2023.

[0081] REFERENCE SIGNS LIST 1 laminated core manufacturing apparatus 10 upper die 11, 12 punch 13, 14 punch 15 stripper 16 punch holder 19 holding portion 20 lower die 21, 22 die 21a, 22a die hole 23, 24 die 23a, 24a die hole 25 adhesive application portion 25a discharge port 26 die shoe 26a, 26b discharge hole 26c, 26d discharge hole 27 lifter portion 27a relief portion 28 die plate 30 punching portion 44 die 45 adhesive application portion 45a discharge port 47 lifter portion 47a relief portion 60 feeding device 80 workpiece 81 core piece 83 pilot hole 85 laminated core

Claims

1. A laminated core manufacturing apparatus which presses intermittently transported strip-shaped workpiece to obtain core pieces of a predetermined shape, and stacks a plurality of these core pieces to manufacture a laminated core, the apparatus comprising: an application section which applies a plurality of connecting means to processing target portions of the workpiece which correspond to the core pieces, for connecting the stacked core pieces together; a punching section which punches out the processing target portions to which the connecting means have been applied from the workpiece to obtain the core pieces; and a lifter section consisting of one or a plurality of plate-like bodies which supports from below the workpiece which is transported at least from the application section to the punching section, the lifter section being provided with a plurality of recesses which are continuous in the transport direction of the workpiece and which overlap with the positions of the connecting means in the transported workpiece, and which supports the workpiece by contacting positions on the workpiece where there are no connecting means at locations which are not the recesses.

2. A laminated core manufacturing apparatus as described in claim 1, wherein the punching section has a punch arranged above the workpiece and a die arranged below the workpiece, and is capable of forming the core pieces by punching out the portion of the workpiece to be processed that is positioned between the punch and die, and the lifter section positions the underside of the workpiece and the connecting means above the upper end of the die, at least while the workpiece is being transported.

3. A laminated core manufacturing apparatus as described in claim 2, wherein the lifter section is capable of supporting the workpiece when no external force is being applied thereto so that the underside of the workpiece and the connecting means are positioned above the upper end of the die, and the punching section has a pressing section which is capable of moving relatively in the vertical direction with respect to the die, and the pressing section presses the lifter section downward relatively from above as the portion to be processed is punched out of the workpiece, so that the underside of the workpiece supported by the lifter section comes into contact with the upper end of the die.

4. The laminated core manufacturing apparatus according to any one of claims 1 to 3, wherein the application section is an adhesive application section that applies adhesive as the connecting means from below to a plurality of locations of the portion to be processed of the workpiece.

5. A laminated core manufacturing apparatus as claimed in any one of claims 1 to 4, wherein the relief portion of the lifter portion is at least one of a groove, a recess, a notch, a hole, and a gap between the plurality of plate-like bodies constituting the lifter portion, which are continuous in the transport direction of the workpiece.

6. A laminated core manufacturing method in which intermittently transported strip-shaped workpiece is pressed to obtain core pieces of a predetermined shape, and a plurality of such core pieces are stacked to manufacture a laminated core, the method comprising: an application step of applying a plurality of connecting means to processing target portions of the workpiece that correspond to the core pieces, for connecting the stacked core pieces together; and a punching step of punching out the processing target portions, to which the connecting means have been applied, from the workpiece to obtain the core pieces; the workpiece which is transported toward the punching step after at least the application step is supported from below by a lifter portion consisting of one or more plate-shaped bodies, and the lifter portion is provided with a plurality of recesses which overlap with the positions of the connecting means in the transported workpiece, which are continuous in the transport direction of the workpiece, and supports the workpiece by contacting portions of the workpiece which do not have the connecting means at locations other than the recesses.

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