JPH10136618A - Manufacturing method of laminated core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce irregularity in magnetic property in a laminated iron core by rotating iron core pieces relatively, according to the variance of the magnetic properties of the iron core pieces, and integrally-joining them integrally by a fixing means. SOLUTION: In order to reduce core loss variation, layered iron core pieces 50 are divided into three portions, and the three-divided blocks are fixed onto a rotating shaft by turning them at an angle of 120 deg.C to each other. The number of the iron core pieces 50 in one block is 23. Three blocks are formed from the iron core pieces 50 of 69 pieces are stacked for one motor. The layered lowest end, that is, the 23th in the iron core pieces 50 is formed with a through- hole 13 into which a protrusion 12 for caulking of the 22nd iron core piece 50 and an inclined groove 15 for skew are press-fitted. The three blocks of stacked 23 pieces each are press-fitted into the rotating shaft respectively in a turned condition at an angle of 120 deg.C to each other, and the three blocks are fixed integrally on the rotating shaft.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated core used for an electric core such as a motor or a generator.

[0002]

2. Description of the Related Art In this kind of conventional method, Japanese Patent Publication No. 6-37
As shown in Japanese Patent Publication No. 79, four iron core construction blocks are formed by stacking 25 iron core pieces each, and the four iron core construction blocks are rotated by 180 degrees with respect to each other.
At this time, the four iron core constituting blocks are integrally laminated and connected using the opposing caulking projections.

[0003] With such a configuration, the thickness deviation is canceled, the outer shape distortion as a laminated core is eliminated, and even when each core component is laminated and connected inside the die, the die height of the die is not increased. It is designed so that it can be set to a low value corresponding to the thickness of each iron core constituent block.

[0004]

In the above-described conventional method for manufacturing a laminated iron core, even if the deviation of the thickness of the electromagnetic steel sheet used for the laminated iron core can be offset, the magnetic field generated in the rolling process of the electromagnetic steel sheet or the like can be offset. There is a problem that the variation of the iron loss in the laminated core caused by the variation of the characteristics cannot be prevented. Therefore, when such a laminated iron core is used for a motor for electric power steering, for example, the loss torque of the motor becomes large due to the variation in magnetic characteristics such as iron loss, and the return of the steering wheel is deteriorated. there were.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a method of manufacturing a laminated iron core capable of reducing variations in magnetic characteristics of the laminated iron core.

[0006]

According to a first aspect of the present invention, there is provided a method for manufacturing a laminated iron core, wherein the iron core component is relatively rotated in accordance with the variation in magnetic characteristics of the iron core component, and integrated by the fixing means. In this case, they are laminated and connected.

According to a second aspect of the present invention, there is provided a method for manufacturing a laminated iron core, wherein a plurality of blocks are formed by integrally connecting a predetermined number of core component pieces, and the respective blocks are relative to each other in accordance with the variation in magnetic characteristics of each block. And each block is integrally connected by a fixing means.

According to a third aspect of the present invention, there is provided a method for manufacturing a laminated iron core, wherein a plurality of iron core constituting pieces are rotated by a predetermined angle in accordance with the variation in magnetic characteristics for each piece, and the respective iron core constituting pieces are fixed by a fixing means. It is designed to be integrally laminated and connected.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a laminated iron core, wherein the fixing means is performed by fittingly engaging a caulking projection formed on the iron core constituting piece.

According to a fifth aspect of the present invention, there is provided a method of manufacturing a laminated iron core, wherein the iron core component is rotated by a predetermined angle in conjunction with press punching.

[0011] The method for manufacturing a laminated core according to the invention of claim 6 is characterized in that the number of caulking projections formed on one iron core component piece is A and the number of slots formed on the iron core component piece is B. , B / A = integer or A / B = integer.

According to a seventh aspect of the present invention, there is provided a method of manufacturing a laminated iron core, in which slots formed in iron core constituting pieces are skewed at a predetermined angle as a result of being laminated.

According to a eighth aspect of the present invention, there is provided a method of manufacturing a laminated iron core, wherein the iron core constituting piece is used for an armature iron core of a motor of an electric power steering.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a laminated core, wherein a plurality of blocks are formed by integrally connecting a predetermined number of core component pieces, and the respective blocks are relative to each other in accordance with the variation in magnetic characteristics of each block. The armature shaft is inserted into the armature shaft while being rotated, and the respective blocks are integrally connected to each other on the armature shaft by fixing means.

According to a tenth aspect of the invention, there is provided a method for manufacturing a laminated iron core, wherein three blocks are formed.

According to a eleventh aspect of the present invention, there is provided a method of manufacturing a laminated iron core, wherein the core components or the blocks are rotated so as to cancel out the variation in the magnetic characteristics of the plurality of core components or the plurality of blocks. It was made.

[0017]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below with reference to the drawings. Embodiment 1 FIG. FIG. 1 is a sectional view showing a motor of an electric power steering according to Embodiment 1 of the present invention.
In the figure, 1 is a yoke, 2 is a bracket fitted in an opening of the yoke, 3 is a permanent magnet fixed to the inner periphery of the yoke 1 by a holder 4, and 5 is a radial gap between the stator core and the stator. The armature cores are mounted so as to face each other, and are formed from laminated steel plates.

Reference numeral 6 denotes an armature coil mounted in a slot of the armature core, 7 denotes a commutator connected to the lead wire of the armature coil, 8 denotes the commutator, and the armature core 5 is fixed to the armature coil. The rotating shaft 9 is a brush slidably contacting a segment of the commutator 7.

Next, a method of manufacturing the armature core 5 will be described. FIG. 2 is a view showing a step of punching a core component piece from a rolled steel sheet from a first station to a fourth station. In FIG.
A pilot hole drilled at the station, 12 is a skew relief round hole projection which is also a swaging projection provided at the I station, 13 is a shaft hole drilled at the II station, and 14 is a II hole station. , A skew inclined groove provided at the station III, and a hole 16 after the outer shape of the iron core component piece removed at the station IV.

The iron core forming pieces 50 punched by the stations I to IV are pressed into each other by the caulking protrusions 12 and the skew inclined grooves 15 and are integrally fixed. That is, FIG. 3 is a plan view showing the iron core component 50, and FIG. 4 is an enlarged cross-sectional view showing a state where the iron core component 50 is fixed by caulking.

On the other hand, in the rolled steel sheet 10 on which the core component piece 50 is formed by punching, the state of the variation in the magnetic properties is measured in advance. That is, FIG. 5 is a characteristic diagram showing the variation of the iron loss in the rolling direction A of the rolled steel sheet 10, and shows the ratio of the iron loss in each direction when the average of the iron loss in each direction is 100. From the measured characteristic charts, it can be seen that the iron loss increases about every 90 degrees.

Therefore, in the first embodiment, in order to reduce the variation in the core loss, the laminated core component pieces 5 are provided.
0 is divided into three parts, and the three divided blocks are separated by an angle of 1 from each other.
It is rotated at every 20 degrees and fixed to the rotating shaft 8. The number of the core component pieces 50 to be stacked in one block is 23, and since three blocks are formed, 69 core component pieces 50 are stacked for one motor.

Accordingly, in FIG. 4, the lowermost layer, ie, the 23rd iron core constituting piece 50, is formed by the swaging protrusion 12 of the 22nd iron core constituting piece 50 and the skew inclined groove 1
5 are formed. Three blocks 50 every 23 sheets thus laminated integrally
Each of the blocks 1, 502, and 503 is press-fitted into the rotating shaft 8 while being rotated by an angle of 120 degrees, and the three blocks 501, 502, and 503 are fixedly attached on the rotating shaft 8. This state is shown in FIG.

As shown in FIG. 7, the armature core 5 formed by the iron core component pieces 50 stacked as described above has the armature coils 6 wound sequentially in the respective slots 14 and the lead wire of the armature coil 6 is connected to the commutator 7. Connected to the segment.

When the armature core 5 formed by such a method is used for a motor for electric power steering, the loss torque can be greatly improved as compared with the conventional one. 8 shows a loss torque characteristic diagram according to the conventional method, and FIG. 9 shows a loss torque characteristic diagram according to the first embodiment of the present invention. Therefore, the method according to the first embodiment of the present invention has the effect of reducing the loss torque of the motor and improving the return of the steering wheel.

In the first embodiment, the number of slots of the armature core 5 is set to 21 and the number of swaging projections is set to 3, and the number of swaging projections is equal to the number of slots / the number of swaging projections =
Since the configuration is made to be an integer, the angle of rotation of the iron core component pieces 50 stacked on each other can be made uniform, which has the effect of facilitating manufacture.

Embodiment 2 FIG. In the first embodiment, three blocks of the core component pieces 50 stacked in advance are formed,
While these components are rotated in a predetermined direction when they are press-fitted and fixed to the rotating shaft 8, as shown in FIG. 10, before the iron core component 50 is press-fitted and fixed to the rotating shaft 8,
The three blocks may be rotated at an angle of 120 degrees with each other, fixed together by a caulking projection, and fixed to the rotating shaft 8 by press fitting.

Embodiment 3 In the first and second embodiments, the configuration in which the slots 14 of the armature core 5 are skewed is illustrated. However, a configuration in which the slots 14 are not skewed may be employed as shown in FIGS.

That is, in FIG. 11 and FIG.
Is a caulking projection formed so as to protrude at substantially three places on the circumference of the iron core constituting piece 50, and a circular projection is protruded at an angle of about 120 degrees on the circumference. Reference numeral 19 denotes a fitting through hole formed in the laminated lowermost iron core component piece 50, and is formed in a shape in which the caulking projection 18 is press-fitted and fixed.

Embodiment 4 In each of the above embodiments,
The block in which the core component pieces 50 are laminated is rotated by a predetermined angle in accordance with the variation in the magnetic characteristics. The core component piece 50 is pressed from the rolled steel plate 10 by pressing the station I to the station IV. rear,
In conjunction with this, in each of the blocks, for example, in the first block, the iron core constituting piece 50 is crimped every 23 pieces,
5 or the caulking projections 17 are integrally fixed to each other. In the next block, the core component piece 50 is rotated at an angle of approximately 120 degrees in conjunction with the press punching, and the 24th piece of the rotated core component piece 50 is rotated. To the forty-sixth sheet are integrally fixed to each other by using the caulking protrusion 12, the inclined groove 15, or the caulking protrusion 17. In the last block, the iron core constituting piece 50 is rotated at an angle of approximately 240 degrees in conjunction with the press punching, and the 47 th to 69 th of the rotated iron core constituting piece 50 are swaged with the caulking protrusions 12, inclined. It is integrally fixed using the groove 15 or the crimping projection 17.

According to the method according to the fourth embodiment, the three blocks can be integrally fixed by using the caulking projections of the iron core constituting piece 50, and the blocks can be separated from each other. Since it is possible to cope with each according to the assembly of the armature, it is easy to assemble the armature core, and it is possible to apply the present invention to assembling armatures having different models and dimensions.

Embodiment 5 Further, in each of the above-described embodiments, the method in which the iron core constituting pieces 50 are configured for each of the laminated blocks and the blocks are rotated by a predetermined angle in accordance with the variation in the magnetic characteristics has been described. Accordingly, the core component pieces 50 may be rotated by a predetermined angle one by one. In the case of this method, variations in the magnetic characteristics of the iron core component pieces 50 can be extremely reduced.

Embodiment 6 FIG. In the above embodiment, a motor with a brush has been exemplified, but the present invention can be applied to an armature core of a brushless motor as shown in FIG. In FIG. 13, reference numeral 60 denotes an iron core component having six slots. Reference numeral 20 denotes six caulking projections formed on the ring-shaped outer peripheral portion of the iron core component, and 21 denotes the iron core component 6
There are six swaging protrusions formed on the 0 tooth portion. The respective iron core constituting pieces are rotated by a predetermined angle in accordance with the variation in the magnetic characteristics, and each of the caulking projections 20 and 21 is rotated.
Are fixed together.

Embodiment 7 In each of the above-described embodiments, an example in which the iron core constituting pieces are integrally fixed by the caulking projections has been described. However, welding, rivets, screws, or the like may be used as the fixing means.

Embodiment 8 FIG. In each of the above-described embodiments, an example in which the core component pieces or the blocks in which a predetermined number of layers are stacked are rotated by a predetermined angle so as to reduce the variation in the magnetic characteristics is illustrated. If the iron core component pieces or the predetermined number of stacked blocks are rotated by a predetermined angle with respect to each other, variations in magnetic characteristics can be prevented, and when applied as a motor for electric power steering, a motor without loss torque can be provided.

In the above description, the variation in the magnetic properties is exemplified by the measurement of iron loss. However, the variation of the magnetic flux density is measured, and according to the variation, a core component piece or a block in which a predetermined number of layers are laminated is determined. You may make it rotate by an angle.

[0037]

As described above, according to the method for manufacturing a laminated iron core of the first aspect of the present invention, the core components are relatively rotated and fixed in accordance with the variation in the magnetic characteristics of the plurality of core components. Since the means is integrally laminated and connected, there is an effect that variations in magnetic characteristics in the case of being configured as a laminated iron core can be reduced by a simple method.

According to a second aspect of the present invention, there is provided a method for manufacturing a laminated core.
A plurality of blocks are formed by integrally joining a predetermined number of core component pieces, and the respective blocks are relatively rotated according to the variation in the magnetic characteristics of the respective blocks, and the respective blocks are integrally formed by fixing means. The variation of the magnetic characteristics can be reduced very easily and in a short time.

According to a third aspect of the present invention, there is provided a method for manufacturing a laminated core.
When a plurality of core components are rotated by a predetermined angle in accordance with the variation in magnetic characteristics for each sheet, and the respective core components are integrally laminated and connected by the fixing means, the configuration is made as a laminated core. In addition, variations in magnetic characteristics can be extremely reduced.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a laminated core.
Since the fixing means is a caulking projection formed on the iron core component, the iron core component can be securely fixed with a simple configuration.

According to a fifth aspect of the present invention, there is provided a method of manufacturing a laminated core.
Since the iron core component is rotated by a predetermined angle in conjunction with the press punching, the variation in the magnetic characteristics can be surely and quickly reduced.

According to a sixth aspect of the present invention, there is provided a method for manufacturing a laminated core.
When the number of crimping protrusions formed on one iron core component piece is A and the number of slots formed on the iron core component piece is B, B / A = integer or A / B = integer is set. Therefore, a predetermined amount of rotation of the iron core component piece or the block can be reliably and easily performed in correspondence with the slot.

According to a seventh aspect of the present invention, there is provided a method of manufacturing a laminated core.
Since the slots formed in the iron core component pieces are formed in the laminated iron core so as to skew at a predetermined angle, the magnetic characteristics of the laminated iron core are further improved, which has the effect of contributing to the improvement of motor performance.

The method for manufacturing a laminated core according to the invention of claim 8 is as follows.
Since the iron core component is used for the armature iron core of the motor of the electric power steering, there is an effect that the torque loss of the motor can be reduced and the return of the steering wheel can be improved.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a laminated iron core.
A plurality of blocks in which a predetermined number of core component pieces are integrally connected are formed, and each block is relatively rotated according to the variation in the magnetic characteristics of each block and inserted into the armature shaft. In this case, the respective blocks are integrally connected to each other by the fixing means, so that the number of working steps is reduced, and there is an effect that the assembling becomes extremely simple.

In the method for manufacturing a laminated iron core according to the tenth aspect of the present invention, since three blocks of the iron core component pieces are formed, the work of assembling the iron core component pieces is facilitated.

According to the eleventh aspect of the present invention, there is provided a method of manufacturing a laminated iron core, wherein each core component or each block is rotated so as to cancel out the variation in the magnetic characteristics of the plurality of core components or the plurality of blocks. As a result, it is possible to prevent variations in magnetic characteristics, and this has the effect of reliably improving motor performance.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a main part of a motor of an electric power steering according to Embodiment 1 of the present invention.

FIG. 2 is a schematic configuration diagram showing a main part of a step of stamping out a core component piece according to Embodiment 1 of the present invention.

FIG. 3 is a plan view showing an iron core component according to Embodiment 1 of the present invention.

FIG. 4 is a cross-sectional view showing a stacked state of iron core component pieces according to Embodiment 1 of the present invention.

FIG. 5 is a characteristic diagram showing variations in iron loss at different angles of a rolled steel sheet according to Embodiment 1 of the present invention.

FIG. 6 is a sectional view showing the laminated core according to Embodiment 1 of the present invention;

FIG. 7 is a plan view showing an armature according to Embodiment 1 of the present invention.

FIG. 8 is a characteristic diagram showing a loss torque of a conventional electric power steering motor.

FIG. 9 is a characteristic diagram showing a loss torque of the electric power steering motor according to the first embodiment of the present invention.

FIG. 10 is a perspective view showing a laminated core according to Embodiment 1 of the present invention;

FIG. 11 is a plan view showing an iron core component according to Embodiment 3 of the present invention.

FIG. 12 is a cross-sectional view showing a laminated state of core component pieces according to Embodiment 3 of the present invention.

FIG. 13 is a plan view showing an iron core constituting piece according to Embodiment 6 of the present invention.

[Explanation of symbols]

Reference Signs List 5 armature core 8 rotating shaft 10 rolled steel plate 12 caulking projection for skew 13 shaft hole 14 slot 15 inclined groove for skew 16 hole for outer shape removal 18 caulking projection 17, 19 fitting through hole 20, 21 projection for caulking 50 iron core Component piece 60 Iron core component piece 501, 502, 5
03 blocks

Claims (11)

[Claims] 1. A method of manufacturing a laminated iron core, wherein said iron core constituting pieces are relatively rotated in accordance with the variation in magnetic characteristics of the iron core constituting pieces, and are integrally laminated and connected by fixing means. 2. A method according to claim 1, further comprising: forming a plurality of blocks in which a predetermined number of core component pieces are integrally joined, rotating each of the blocks relative to each other in accordance with the variation in the magnetic characteristics of each of the blocks. A method for manufacturing a laminated core, wherein the laminated core is integrally joined by a fixing means. 3. A laminated iron core in which a plurality of iron core components are rotated by a predetermined angle in accordance with variations in magnetic characteristics for each one, and the core components are integrally laminated and connected by a fixing means. Production method. 4. The laminated iron core according to claim 1, wherein the fixing means is performed by fitting and engaging a caulking projection formed on the iron core constituting piece. Manufacturing method. 5. The method for manufacturing a laminated core according to claim 1, wherein the core constituting piece is rotated by a predetermined angle in conjunction with press punching. 6. A / B = integer or A / B = where A is the number of caulking projections formed on one iron core component piece and B is the number of slots formed on the iron core component piece. The method for manufacturing a laminated iron core according to claim 4, wherein the number is set to be an integer. 7. The method for manufacturing a laminated core according to claim 1, wherein the slots formed in the core constituting pieces are skewed at a predetermined angle as a result of being laminated. 8. The method for manufacturing a laminated iron core according to claim 1, wherein the iron core constituting piece is used for an armature iron core of an electric power steering motor. 9. A plurality of blocks in which a predetermined number of core component pieces are integrally connected are formed, and each block is relatively rotated according to the variation in magnetic characteristics of each of the blocks and inserted into the armature shaft. And a method of manufacturing a laminated core in which respective blocks are integrally connected on an armature shaft by fixing means. 10. The method for manufacturing a laminated iron core according to claim 9, wherein three blocks are formed. 11. A method for manufacturing a laminated iron core, characterized in that each core component or each block is rotated so as to cancel out variations in magnetic characteristics of a plurality of core components or a plurality of blocks. .