Method for manufacturing laminated core

A method for manufacturing a laminated core includes (1) blanking a rotor core sheet 15 and a stator core sheet 14 from a thin strip material 27 and (2) laminating the stator core sheet 14 inside a die. The stator core sheet 14 includes a ring-shaped yoke piece 18 and plural magnetic pole pieces 19 integrally connecting to a radially inside of the yoke piece 18. Each of the magnetic pole pieces 19 includes a magnetic pole shaft piece 20 and a magnetic pole tooth piece 21. The magnetic pole pieces 19 are formed by blanking preparatory slots 29; coining a part or a whole of the magnetic pole shaft pieces 20 to elongate the same in a radially inward direction; and thereafter, blanking the finishing slots 30 and shaping the magnetic pole tooth pieces 21.

TECHNICAL FIELD

The present invention relates to a method for manufacturing a laminated core which is applicable to, for example, a stepping motor. The method is highly productive and operable to produce stator core sheets from a thin strip material (magnetic steel sheet) with a high yield.

BACKGROUND ART

Conventionally, a laminated core for a stepping motor has a very small air gap between a rotor and a stator. When a rotor core sheet and a stator core sheet, respectively used for the rotor and the stator, are produced from one thin strip material, small metal clippings are formed in narrow gaps therebetween. The metal clippings may be broken during a punching operation and not drop into a downside of a die, a part of a die device, thereby requiring the punching operation again. What is worse, the die device may be damaged due to clogging of scraps including the metal clippings.

If magnetic pole pieces, specifically magnetic pole teeth located radially inside the stator core sheet, cannot be blanked in a desired shape, the rotor core sheet and the stator core sheet have to be blanked using the different die devices, which results in a low material yield and a high cost.

Patent Literature 1 discloses an example of the conventional art to solve the above problems. In Patent Literature 1, at least one of the rotor core sheet and the stator core sheet are coined, specifically, pressed in a thickness direction and evenly elongated so as to form thin sections. Further, both of the rotor core sheet and the stator core sheet can be produced from one magnetic steel sheet using one die device.

In a method for manufacturing a laminated core of Patent Literature 1, the thin section is elongated in a circumferential direction, and bulges are formed in an area where a wire is wound. As a countermeasure, Patent Literature 2 discloses a finishing blanking for eliminating the bulges on lateral sides of the magnetic pole teeth.

CITATION LIST

Patent Literature

SUMMARY OF INVENTION

Technical Problem

In the technique of Patent Literature 1, when the thin section is formed by coining, especially when a tip of a magnetic pole is elongated in a radial direction, one side (top or underside) of a magnetic pole piece is pressed in the thickness direction. For this reason, the magnetic pole piece becomes distorted, and caulking accuracy and dimensional accuracy of a core diameter become unstable. When the magnetic pole piece is deeply pressed to increase the elongation, the magnetic pole piece is largely distorted, causing an adverse effect on product quality.

In the technique of Patent Literature 2, the bulges are created in the circumferential direction when the thin section is formed, and only the bulges are eliminated. However, when a magnetic pole shaft piece is pressed, an inclination (deformation) arises not only in the magnetic pole shaft piece but also in a magnetic pole tooth piece integrally formed radially inside the magnetic pole shaft piece. Further, the more the elongation is increased by thinning the magnetic pole shaft piece, the larger and the deeper the magnetic pole shaft piece is pressed, which causes the distortions in entire slots and pilot holes. These distortions cannot be modified sufficiently by the technique of Patent Literature 2, and in some cases, blanking accuracy after coining is deteriorated, and a laminated core formed by laminating blanked stator core sheets has a variation in magnetic properties of magnetic poles.

In view of the above circumstances, an object of the present invention is to provide a method for manufacturing a laminated core, capable of elongating a magnetic pole piece without creating distortion at the formation of the thin section. The method can further improve caulking accuracy and dimensional accuracy of the laminated core when a rotor core sheet and a start core sheet are produced from one thin strip material.

Solution to Problem

To accomplish the above object, a method for manufacturing a laminated core according to the present invention comprises: a first step of punching out a rotor core sheet and a stator core sheet from a thin strip material, the stator core sheet positioned so as to have a common axis with the rotor core sheet, the stator core sheet including a ring-shaped yoke piece and a plurality of magnetic pole pieces, the magnetic pole pieces integrally connecting to a radially inside of the yoke piece, each of the magnetic pole pieces including a magnetic pole shaft piece and a magnetic pole tooth piece; and a second step of laminating the stator core sheet inside a die; wherein in order to form the magnetic pole pieces, firstly preparatory slots, smaller than finishing slots, are blanked, the adjacent finishing slots forming each of the magnetic pole pieces; secondly a part or a whole of the magnetic pole shaft pieces each are coined to elongate the magnetic pole pieces in a radially inward direction; and thereafter the finishing slots are blanked and the magnetic pole tooth pieces are shaped.

In the method for manufacturing the laminated core according to the present invention, it is preferable that bending deformations of the magnetic pole shaft pieces caused by coining are straightened at the same time with, or before or after the formation of the finishing slots.

Generally, if a part or whole of the magnetic pole shaft piece is coined (i.e., pressed to reduce the thickness), the magnetic pole shaft piece located inside the coined portion and the magnetic pole tooth pieces connected thereto are distorted, and such distortions (bending deformations) are straightened by pushing with a press or holding with a stripper. Especially when the adjacent magnetic pole tooth pieces are connected to each other, a radially inside of the stator core sheet is bent upwardly (or downwardly). This bent portion is straightened and planarized, as the material undergoes plastic deformation.

In the method for manufacturing the laminated core according to the present invention, it is preferable that a length of the elongation of the magnetic pole piece is within 30-80% (preferably 46-65%, more preferably 50-60%) of a thickness of the thin strip material.

If the elongation length of the magnetic pole piece is short, the elongation of the magnetic pole tooth piece in a radial direction is insufficient. If the elongation is too much, the material thickness becomes thin and magnetic properties are deteriorated, and further the magnetic pole piece becomes largely deformed.

In the method for manufacturing the laminated core according to the present invention, it is preferable that first pilot holes are formed in the thin strip material in a initial process; with reference to the first pilot holes, the rotor core sheet and the preparatory slots are blanked, the magnetic pole shaft pieces are coined, and the finishing slots are formed; at the same time with or after the formation of the finishing slots, second pilot holes are formed with reference to the finishing slots; and subsequent press works are performed with reference to the second pilot holes. This enables the stator core sheet to be formed more precisely.

In this case, it is preferable that the second pilot hole has a larger diameter than the first pilot hole, and the second pilot hole is formed so as to overlap the first pilot hole.

Here, the second pilot hole may be placed in a different position from the first pilot hole.

Also in this method, it is preferable that the vertically adjacent stator core sheets are interlocked and laminated via caulking portions, and the caulking portions are formed with reference to the second pilot holes.

In the method for manufacturing the laminated core according to the present invention, it is preferable that the magnetic pole tooth pieces are formed by: blanking first slits forming adjacent small teeth located radially inside the magnetic pole tooth pieces, and second slits forming the adjacent magnetic pole pieces, in a manner that an annular piece located radially inside the magnetic pole tooth pieces is left attached; and then blanking the annular piece so as to form radially inner ends of the small teeth.

In this case, it is preferable that the annular piece has a minimum radial length of 0.1 mm or more. This enables the annular piece to be cut out, with its annular shape retained.

Advantageous Effects of Invention

In the method for manufacturing the laminated core according to the present invention, in order to form the magnetic pole pieces, firstly the preparatory slots, smaller than the finishing slots, are blanked, the adjacent finishing slots forming each of the magnetic pole pieces; secondly a part or a whole of the magnetic pole shaft pieces each are coined to elongate the magnetic pole shaft pieces in a radially inward direction; and thereafter the finishing slots are blanked and the magnetic pole tooth pieces are shaped. Thus, the coined portions of the magnetic pole shaft pieces can be stably elongated. Also, the finishing slots are blanked after the coining of the magnetic pole shaft pieces, so that entire slots, including the magnetic pole pieces deformed by coining, can be formed in a predetermined dimension. As a result, dimensional accuracy for finishing the stator core sheet can be improved.

The magnetic pole shaft pieces and the magnetic pole tooth pieces connected thereto are deformed by coining. Such deformations (distortions) caused by coining are straightened at the same time with, or before or after the formation of the finishing slots, thereby removing the deformations and planarizing the stator core sheet.

In the method for manufacturing the laminated core according to the present invention, the magnetic pole piece is elongated such that the length of the elongation thereof is within 30-80% of the thickness of the thin strip material, thereby securing sufficient areas for forming the small teeth inside the stator core sheet.

In the method for manufacturing the laminated core according to the present invention, the first pilot holes are formed in the thin strip material in the initial process; with reference to the first pilot holes, the rotor core sheet and the preparatory slots are blanked, the magnetic pole shaft pieces are coined, and the finishing slots are formed; at the same time with or after the formation of the finishing slots, the second pilot holes are formed with reference to the finishing slots; and the subsequent press works are performed with reference to the second pilot holes. Therefore, the deformation of the stator core sheet caused by coining can be modified twice, thereby manufacturing the stator core sheet with higher accuracy.

Here, the second pilot hole has the larger diameter than the first pilot hole, and the second pilot hole is formed so as to overlap the first pilot hole. Therefore, the stator core sheet can be efficiently produced from the thin strip material, and areas where the first pilot holes are formed can be used effectively.

Further, the vertically adjacent stator core sheets are interlocked and laminated via the caulking portions, and the caulking portions are formed with reference to the second pilot holes. Therefore, the caulking portions can be arranged with reference to the positions of the magnetic pole pieces.

In the method for manufacturing the laminated core according to the present invention, the magnetic pole tooth pieces are formed by: blanking the first slits forming the adjacent small teeth located radially inside the magnetic pole tooth pieces, and the second slits forming the adjacent magnetic pole pieces (magnetic pole tooth pieces), in a manner that the annular piece located radially inside the magnetic pole tooth pieces is left attached; and then blanking the annular piece so as to form the radially inner ends of the small teeth. Therefore, the dimensional accuracies of the grooves between the small teeth and circular arcs of the radially inner ends of the small teeth can be improved. In addition, accuracy of a punch (male die) can be improved, thereby enhancing an operating life of the punch.

In this case, the annular piece has the minimum radial length of 0.1 mm or more, which enables the annular piece to be cut out, with its annular shape retained. Therefore, the dimensional accuracy of a circle inside the small teeth can be improved.

DESCRIPTION OF EMBODIMENTS

FIG. 1shows a stator core10and a rotor core11, manufactured by a method for manufacturing a laminated core according to one embodiment of the present invention. The stator core10and the rotor core11are used for a stepping motor. The stator core10includes a yoke section12having an annular shape when viewed from the top and a plurality of magnetic pole sections13provided inside the yoke section12. The stator core10and the rotor core11are respectively formed by caulking (interlocking) and laminating stator core sheets14and rotor core sheets15, and both of the core sheets14,15are made of a magnetic steel sheet. Here, reference signs16,17indicate caulking (interlocking) portions, and a reference sign17aindicates a shaft hole. The caulking portions16,17are well-known half-press caulking (half-hollow rivet) or V-shaped caulking.

As shown inFIGS. 2(A) and2(B), the stator core sheet14includes a ring-shaped yoke piece18and a plurality of (eight in this embodiment) magnetic pole pieces19integrally formed radially inside the yoke piece18. The magnetic pole piece19includes a magnetic pole shaft piece20integrally formed inside the yoke piece18and a magnetic pole tooth piece21integrally formed inside the magnetic pole shaft piece20. The magnetic pole tooth piece21includes a plurality of small teeth22radially inside thereof.

In this embodiment, a part (or a whole) of each of the magnetic pole shaft pieces20is coined to form a groove24having a uniform radial length. The grooves24are aligned in a circumferential direction (i.e., located on the same circumference). And, a thin section25is formed in the groove24.

As shown inFIGS. 3 and 4, in the method for manufacturing the laminated core according to one embodiment of the present invention, a thin strip material27made of the magnetic metal sheet is fed into a die device (progressive die) having stations (A)-(K), thereby manufacturing the laminated core through processes (A)-(K). Hereinafter, the detail descriptions thereon will be given.

In the station (A), namely, in the process (A) (hereinafter the same shall apply), a pair of first pilot holes28and preparatory slots29are formed in the thin strip material27. The preparatory slots29rough out circumferential shapes in the magnetic pole shaft piece20and the magnetic pole tooth piece21of the stator core sheet14. In this embodiment, the stator core sheet14includes eight (plural) magnetic pole pieces19, thus the eight preparatory slots29are formed at once.

Here, the preparatory slot29is smaller than a finishing slot30, described hereinbelow, and includes a little allowance therearound. For example, the allowance may be 0.5-10 times the material thickness.

In the station (B), a positioning of the thin strip material27is performed with the first pilot holes28, and the caulking portions17and a shaft hole17aof the rotor core sheet15are blanked.

The station (C) is an idle station.

The rotor core sheet15and the stator core sheet14are formed so as to have a common axis.

In the station (D), the rotor core sheet15is blanked and dropped into a die (female die), and laminated inside the die, thereby forming the rotor core11. In the station (E), with reference to the first pilot holes28, the magnetic pole shaft pieces20defined by the preparatory slots29are equally coined by pressing parts of the magnetic pole shaft pieces20using a ring-shaped punch.

In this case, a stripper provided in the die device holds areas radially outside the coined portions (grooves24) such that areas radially inside the same are open. Thus, an excess thickness created by coining moves (expands) to the areas radially inside the coined portions. The magnetic pole shaft piece20is elongated in the radially inward direction by coining, so that the elongation length of the magnetic pole shaft piece20is 30-80% of the thickness of the thin strip material27.

Preferably, the groove24(corresponding to the thin section25) formed by coining is located in an innermost part of the magnetic pole shaft piece20. This arrangement can minimize the deformation of the elongated magnetic pole tooth piece21.

A volume of the portion elongated by coining (a material thickness “t”× a width of the magnetic pole shaft piece20× an elongated length) is approximately equal to a volume of the groove24(a depth of the groove24× the width of the magnetic pole shaft piece20× a radial length “a” of the groove24). If the groove24is too deep, magnetic properties of the magnetic pole shaft piece20become worse. Thus, the depth of the groove24is preferably within 0.1-0.5 times, more preferably 0.1-0.4 times, the material thickness (SeeFIG. 2(B)).

In this embodiment, the adjacent magnetic pole tooth pieces21are connected to each other in the circumferential direction. If the magnetic pole shaft pieces20are elongated in the radially inward direction, the magnetic pole shaft pieces20are deformed by coining. In particular, the magnetic pole tooth pieces21are bent upwardly. Such bending deformations are pressed (straightened) in the next station (F). Specifically, the thin strip material27is pressed with the stripper used in the station (F). Alternatively, a station for straightening the bending deformations may be provided between the stations (E) and (F), or after the station (F).

In the station (F), with reference to the first pilot holes28created in the initial process, the second pilot holes32are formed to overlap the first pilot holes28in a manner that the second pilot holes32have a larger diameter than that of the first pilot holes28located at the downstream side of the straightened thin strip material27. In other words, pilot holes are redefined and recreated. Also in the station (F), the finishing slots30are blanked, forming final shapes of the magnetic pole shaft pieces20and the circumferential shapes of the magnetic pole tooth pieces21. At this time, the finishing slot30is blanked so as to include a whole or a large part of the circumference of the preparatory slot29.

Alternatively, the second pilot hole32may be placed in a different position from the first pilot hole28. Also, the second pilot hole32may be formed with reference to the finishing slot30after the formation thereof.

In the station (G), first slits33and second slits34are blanked with reference to the second pilot holes32. The first slits33outline the small teeth22located radially inside the magnetic pole tooth piece21, and the second slits34outline the adjacent magnetic pole tooth pieces21.

Referring toFIG. 5, a detail description will be given on the first slit33and the second slit34.

InFIG. 5, the first slit33and the second slit34are shown by hatching. An outline37of the preparatory slot29is shown by a two-dot chain line. Also, an outline38of the preparatory slot29, elongated in the radial direction at the coining of the magnetic pole shaft piece20, is shown by a two-dot chain line. The outline38is inside the outline37. A two-dot chain line39indicates an outline of the blanked rotor core sheet15before coining, and a solid line40indicates the outline of the same after coining.

The second slit34is blanked to partly include a forming region of the finishing slot30. In other words, the outlines of the second slit34and the finishing slot30cross each other (i.e., the outlines are mismatched), so that slightly depressed portions “M” are formed in the small teeth22located at the both lateral sides of the magnetic pole tooth piece21. Since the blanking lines are overlapped like this, portions between the adjacent outlines of the second slit34and the finishing slot30can be blanked without being left, and also generation of burrs can be prevented.

In the station (H), the caulking portions16are formed with reference to the second pilot holes32. A lowermost stator core sheet14of the stator core10has the caulking portions16each formed by a through hole, and the stator core sheets14subsequently laminated thereon have downwardly protruding caulking portions16. The station for forming the through holes may be provided as a separate stage before the station (H).

In the stator core sheet14as shown inFIGS. 1 and 2, the caulking portions16are formed alternately on the radially outside and the inside of the magnetic pole pieces19. However, as shown in the station (H) and subsequent stations inFIG. 4, the caulking portions16may be formed radially inside the magnetic pole pieces19and in the yoke piece18in a pitch of two magnetic poles. To further improve the magnetic properties, the caulking portions16may be formed only in the yoke piece18.

In the station (I), a circle with radius “r,” forming inner end lines of the small teeth22, is blanked. A solid line41shows outlines of the small teeth22formed by this blanking. As shown inFIG. 5, a metal clipping (scrap)44of an annular piece is removed, which is defined by an outline of the circle with radius “r” and a solid line40. As a result, the formation of the magnetic pole tooth pieces21is completed, forming the small teeth22throughout the stations (F), (G), and (I).

In a last step for forming the small teeth22, the small teeth22may be formed using the die device (punch and die) which has shapes of grooves between the small teeth22and radially inner ends of the small teeth22. However, configuration of the die device becomes complicated. In this embodiment, the grooves and the radially inner ends of the small teeth22are blanked using the different punches and dies, thereby generating the annular metal clipping44. Thus, it is advantageous that the punches and dies can be easily manufactured and maintained.

Here, the metal clipping44has a minimum radial length “c” of 0.1 mm (more preferably 0.2 mm) or more.

In the next station (J), an outline of the stator core sheet14is blanked, and interlocked and laminated inside the die (female die).

The station (K) inFIG. 4shows the thin strip material (skeleton) after the stator core sheet14and the rotor core sheet15are blanked.

The present invention is not limited to the above-stated embodiment and can include modifications in the dimensions, numbers of the magnetic poles, and shapes of the magnetic pole teeth made within the gist of the present invention.

Furthermore, the present invention is applicable to a laminated core formed with normal stator core sheets, which do not include the small teeth inside the magnetic pole tooth pieces.

INDUSTRIAL APPLICABILITY

In a method for manufacturing a laminated core according to the present invention, a stator core sheet includes magnetic pole shaft pieces and magnetic pole tooth pieces connecting thereto which are formed in precise shapes, thereby reducing a gap between a rotor and a stator as well as manufacturing a motor with a high torque. Furthermore, a rotor core sheet and the stator core sheet are produced from a strip of magnetic steel sheet concentrically, thereby improving material yields of the laminated core.

REFERENCE SIGNS LIST

10: stator core,11: rotor core,12: yoke section,13: magnetic pole section,14: stator core sheet,15: rotor core sheet,16,17: caulking portion,17a: shaft hole,18: yoke piece,19: magnetic pole piece,20: magnetic pole shaft piece,21: magnetic pole tooth piece,22: small teeth,24: groove,25: thin section,27: thin strip material,28: first pilot hole,29: preparatory slot,30: finishing slot,32: second pilot hole,33: first slit,34: second slit,37: outline of preparatory slot,38: outline of elongated preparatory slot,39: two-dot chain line (blanking outline of stator core sheet before coining),40: solid line (blanking outline of stator core sheet after coining),41: solid line (bore diameter of small teeth),44: metal clipping (scrap), M: depressed portion