JP4898381B2 - Manufacturing method of deformed iron core - Google Patents

Description

The present invention relates to a method of manufacturing a deformed iron core that is used in a reluctance resolver or a variable reluctance resolver for measuring rotation speed, rotation angle, position detection, and the like.

As a reluctance type resolver or a variable reluctance type resolver, for example, Patent Document 1 discloses its structure and operation, and Patent Document 2 also describes its structure and operation in detail. Stacked deformed iron cores are used. The core pieces that make up these laminates need to be firmly integrated in order to increase measurement accuracy and detection accuracy. For this reason, each core piece (iron core piece) is connected by caulking using caulking projections and caulking recesses. Has been.
With reference to FIG. 4, an example of a method for manufacturing the deformed core 52 having the two types of first and second laminated bodies 50 and 51 will be described. In the deformed iron core 52 shown in FIG. 4A, the core pieces 53 and 54 of the first and second laminates 50 and 51 have different external shapes with respect to the shaft hole (not shown) and the plurality of caulking portions 55. Therefore, as shown in FIGS. 4B and 4C, a plurality of stacked bodies 50 and 51 are stacked in a vertical direction using separate mold apparatuses (not shown).

As shown in FIG. 4B, each first laminated body 50 is formed by connecting four core pieces 53 via a plurality of caulking portions 55 including caulking projections 56 and caulking concave portions 57. The lowermost core piece 53 of one laminated body 50 is formed with a caulking hole 58 instead of the caulking concave portion 57, so that the first laminated body 50 can be easily separated vertically.
Further, as shown in FIG. 4C, each second laminated body 51 is formed by punching and laminating two core pieces 54 via idle core pieces 59. The idle core piece 59 is provided with a caulking hole 60 into which a caulking protrusion 56 provided in the upper core piece 54 is fitted, and the upper and lower second laminated bodies 51 provided with the idle core piece 59 at the bottom can be separated. It is like that. In assembly, the idle core piece 59 provided at the bottom of the second laminated body 51 is removed, and the second laminated body 51 is placed on the first laminated body 50 and caulked and joined. Two deformed iron cores 52 are manufactured.

JP 2002-39794 A JP 2005-164486 A

In the method for manufacturing the deformed iron core described above, there is a problem that the idle core piece 59 provided at the bottom of the second laminate 51 is wasted.
When the first and second laminates 50 and 51 are manufactured independently using separate mold apparatuses, the bottom of the second laminate 51 is laminated on one deformed iron core without providing an idle core piece. Although it is possible to manufacture more continuously, it is necessary to remove the second laminated body incorporated (laminated) into one deformed iron core from among the laminated layers. Since this removal is to release the fitting of the caulking projection 56 and the caulking concave portion 57 between the laminated core pieces 54, labor and time are required. Further, there is a problem that the caulking protrusion 56 protruding downward is deformed and may not be properly fitted into the caulking recess 57 at the upper part of the first laminated body 50. Moreover, when manufacturing both the 1st and 2nd laminated bodies 50 and 51 with one metal mold apparatus, it is necessary to change the metal mold | die outside an outline, and it is an effort.
This invention is made | formed in view of this situation, and it aims at providing the manufacturing method of the deformed iron core which improved productivity and material yield.

The manufacturing method of the deformed iron core according to the first invention in accordance with the above object includes a first laminated body obtained by caulking and laminating a first core pieces of the same shape, and caulking and laminating on the first laminated body, A method of manufacturing a deformed iron core having a second laminated body obtained by caulking and laminating b second core pieces having different shapes from the first core piece,
A caulking concave portion or a caulking concave portion in which a caulking protrusion formed on the second core piece at the lowermost part of the second laminated body laminated on the first core piece is closely fitted to the first core piece every a pieces A caulking hole is formed, and the first core piece for each a and the first core piece disposed in the lower part thereof are caulked and laminated , and the first lowermost part of the first laminated body is the first Only a caulking hole is formed in the core piece, and the first laminated body is formed so that the first laminated body can be individually separated,
A caulking recess or a caulking hole into which the caulking projection of the second core piece placed on the upper part is loosely fitted is formed on the second core piece every b sheets, and the second core piece and the lower part thereof every b sheets The second core piece is caulked and laminated to form a second connected laminated body so that the second laminated body can be individually separated, and the first laminated body is separated from the first laminated body. The body is taken out, the second laminated body is taken out from the second connected laminated body, and these are caulked and laminated.
In addition, this invention is applied with respect to the adjacent laminated body which comprises a deformed iron core, for example, three or more laminated bodies may exist in a deformed iron core.

The method for manufacturing a deformed iron core according to the second invention is the method for manufacturing a deformed iron core according to the first invention, wherein the first core and the first core adjacent to each other of the second stack are stacked. The positions of the caulking protrusions formed on the pieces, the second core pieces, and the first and second core pieces are different, and the position of the caulking protrusion is one or two different positions in plan view. It is the same.

According to a third aspect of the present invention, there is provided a method for manufacturing a deformed iron core according to the first or second invention. The method for manufacturing a deformed iron core according to the first or second invention includes a caulking protrusion on a core piece disposed in a lower portion above the second laminate. A caulking portion or a caulking hole made up of a caulking concave portion is formed, and a caulking portion made up of a caulking protrusion and a caulking concave portion that closely fits into the caulking concave portion or the caulking hole of the lower core piece is provided in the core piece arranged above the caulking concave portion. One or two or more laminates of different shapes that are further caulked and laminated are polymerized through the caulking connection means.

And the manufacturing method of the deformed iron core which concerns on 4th invention is a manufacturing method of the deformed iron core which concerns on 3rd invention, The bottom part of the connection laminated body except the said 1st connection laminated body WHEREIN: This connection laminated body of A bottom core piece having the same shape as the core piece and provided with a caulking hole into which a caulking protrusion of the lowermost core piece of the connected laminated body is loosely fitted is provided.

In the method for manufacturing a deformed iron core according to any one of claims 1 to 4, since the first and second connected laminated bodies in which the first and second core pieces having the same shape are stacked are produced, the first laminated body. And the 2nd laminated body can be manufactured continuously, it is not necessary to replace | exchange a metal mold | die in the middle, and the 1st, 2nd connection laminated body can be manufactured with sufficient productivity. In addition, when manufacturing the 1st, 2nd connection laminated body with one metal mold apparatus, although replacement | exchange of a metal mold is required, each required number of 1st, 2nd laminated bodies are continuously connected. Is efficient.
And in the 1st connection lamination body, it is caulking formed in the 1st core piece for every a sheet, and the 2nd core piece of the lowermost part of the 2nd laminations laminated on the 1st core piece. A caulking concave portion or a caulking hole in which the protrusion is closely fitted is formed, and the first core piece for each a and the first core piece disposed in the lower part thereof are caulked and laminated to form a first laminated body. Individually separable. Moreover, in the 2nd connection laminated body, while forming the caulking recessed part or the caulking hole which the caulking protrusion of the 2nd core piece mounted on top loosely fits into the 2nd core piece for every b sheets, and b The second core piece for each sheet and the second core piece disposed under the second core piece are caulked and laminated so that the second laminated bodies can be individually separated. Therefore, the first and second stacked bodies can be formed without waste by improving the yield of the material, and the second stacked bodies are formed on the first stacked bodies individually taken out from the first and second connected stacked bodies. Caulking lamination of the laminate is possible.

In particular, the method for manufacturing a deformed iron core according to claim 2 includes the first core pieces, the first core pieces adjacent to each other in the upper and lower sides of the first laminated body and the second laminated body, the second core pieces, and the first and second laminated bodies. The positions of the caulking protrusions formed on the second core piece are different, and the positions of the caulking protrusions are the same when viewed in plan, with one or two differences between the upper and lower sides, so that the mold configuration is facilitated.

The method for producing a deformed iron core according to claim 3 includes forming a caulking portion or a caulking hole including a caulking projection and a caulking concave portion in a core piece arranged in a lower portion above the second laminated body, and arranging the caulking portion or caulking hole in the upper portion. The core piece is provided with a caulking projection and a caulking portion formed by caulking concave portions or a caulking concave portion of the lower core piece that are closely fitted into the caulking hole. Since one or more bodies are polymerized, a deformed iron core having a multi-layered laminate can be produced. In this case, the caulking connection means is also used for the connecting portion of the first stacked body and the second stacked body.

And the manufacturing method of the odd-shaped iron core of Claim 4 is the same shape as the core piece of a connection laminated body in the bottom part of the connection laminated body except a 1st connection laminated body, Comprising: The lowest part of a connection laminated body Since the bottom core piece provided with the caulking hole into which the caulking protrusion of the core piece is loosely fitted is provided, it is possible to protect the caulking protrusion protruding from the lower end portion of each connection laminate. In this case, this bottom core piece is removed and discarded when assembling the deformed core, but since it is one piece for each connected laminated body, it is compared with the case of discarding one piece for each conventional laminated body. Then the yield is much better.

Subsequently, an embodiment of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
1A is a partially omitted sectional view of the third stacked body, FIG. 1B is a partially omitted sectional view of the second stacked body, and FIG. 1C is a partially omitted sectional view of the first stacked body. Sectional drawing, (D) is a partially omitted sectional view of a deformed iron core manufactured by a method according to an embodiment of the present invention combining them, and FIG. 2 (A) is a partially omitted third connection laminate. Sectional drawing, (B) is a partially omitted sectional view of the second connecting laminate, (C) is a partially omitted sectional view of the first connecting laminate, and FIG. 3 is a method according to an embodiment of the present invention. It is a top view of the deformed iron core manufactured by 1. 1 and 2, the laminate is cut in an arc shape so that the caulking portion of each laminate has a cross section.

The deformed iron core 10 manufactured by the method according to the embodiment of the present invention has first to third laminated bodies 11 to 13 as shown in FIGS. An even number of first core pieces 14 to 17, second core pieces 18 and 19, and third core pieces 20 to 23 made of magnetic iron plates, which respectively constitute the first to third laminated bodies 11 to 13 ( In this embodiment, six are laminated by caulking portions formed at predetermined positions.
The first core pieces 14-17, the second core pieces 18, 19, and the third core pieces 20-23 have a common shaft hole 24a. The outer circles of the core pieces 20 to 23 are formed eccentrically from the shaft hole 24a and have different shapes.

Next, a method for manufacturing the deformed iron core 10 will be described. As described above, in the present embodiment, the three first core pieces 14 to 17, the second core pieces 18 and 19, and the third core pieces 20 to 23 are different from each other. However, when these core pieces are manufactured, it is necessary to change the mold in the middle, which is troublesome. Therefore, the first core pieces 14 to 17, the second core pieces 18 and 19, and the third core pieces 20 to 23 having the same shape are shared and manufactured using three mold apparatuses. This has the advantage that the mold need not be changed frequently. A large number of first core pieces 14 to 17 are manufactured using a single mold apparatus, and then the second core pieces 18 and 19 are manufactured in large quantities by changing the mold. Even when a large number of the three core pieces 20 to 23 are manufactured, the replacement of the mold is minimal, and the present invention is applied.

First, the case where the 1st connection laminated body 11a which laminated | stacked the 1st laminated body 11 is manufactured is demonstrated, referring FIG.2 (C). Four (that is, a) first core pieces 14 to 17 are sequentially punched and stacked in order, but only the caulking holes 24 that are examples of caulking portions are formed in the first core pieces 14. In one core piece 15, a known caulking portion 25 having a caulking protrusion 26 on the lower portion and a caulking concave portion 27 on the upper portion and every other caulking hole 24 are alternately formed. In the first core piece 16, caulking portions 25 that are closely fitted into the caulking holes 24 of the first core piece 15 and caulking holes 24 are alternately formed.

The first core pieces 17 are alternately formed with caulking portions 25 and caulking holes 24 that fit into the caulking holes 24 of the first core pieces 16. Since the first laminated body 11 mounted thereon has the same structure, every other caulking connection between the caulking hole 24 and the caulking portion 25 is finally provided in a plan view and connected to each other. A product obtained by laminating a plurality of first laminated bodies 11 including the first core pieces 14 to 17 is manufactured by one mold apparatus. And since the 1st laminated body 11 adjacent to the upper and lower sides is not connected specially, each can be isolate | separated separately.

Next, with reference to FIG. 2 (B), a method for manufacturing the second connected laminated body 12a in which the second laminated bodies 12 are laminated will be described. Before punching out the two second core pieces 18 and 19 of the second laminated body 12 (that is, an example of b pieces), the bottom core piece 28 having the same shape as the first and second core pieces 18 and 19 is punched out. Punch out. In the bottom core piece 28, caulking holes 29 are formed at the positions of all caulking portions. Since the bottom core piece 28 is finally removed, it is preferable that the bottom core piece 28 is loosely fitted into the caulking projection 26 of the caulking portion 25 of the second core piece 18 directly above, thereby easily separating the bottom core piece 28. it can.

A second core piece 18 is laminated on the top of the bottom core piece 28. In the second core piece 18, a caulking portion 25 including a caulking protrusion 26 and a caulking concave portion 27 and a caulking hole 24 are alternately formed. The caulking protrusion 26 is fitted into the caulking hole 29 of the bottom core piece 28. The second core piece 19 has a caulking projection 26 and a caulking concave portion 27 which are closely fitted into the caulking hole 24 of the second core piece 18, and an enlarged diameter caulking hole into which the caulking projection 26 is loosely fitted. Every other 30 is formed.
The second core piece 18 is mounted on the second core piece 19, and the caulking protrusion 26 protruding from the lower portion of the second core piece 18 is fitted into the caulking hole 30 with a gap. To do. Therefore, the second laminated body 12 composed of the two second core pieces 18 and 19 that are caulked and laminated is laminated so as to be separable.

Next, with reference to FIG. 2 (A), a method for manufacturing the third connected laminated body 13a in which the third laminated bodies 13 are laminated will be described. Before the third core piece 20 of the third laminate 13 is punched, the bottom core pieces 32 having the same shape as the four (that is, c) examples of the third core pieces 20 to 23 are punched. The bottom core piece 32 is formed with caulking holes 29 at all caulking positions. The bottom core piece 32 is finally removed in the same manner as in the case of manufacturing the second laminate 12, so that the bottom core piece 32 is loosely fitted into the caulking protrusion 26 of the caulking portion 25 of the third core piece 20 directly above. It is preferable that the bottom core piece 32 can be easily separated.

Next to the bottom core piece 32, the third core piece 20 is formed by stamping, and the caulking portions 25 and the caulking holes 24 are alternately formed in the third core piece 20. Then, the caulking protrusion 26 of the caulking portion 25 is fitted into the caulking hole 29. A third core piece 21 is laminated on the third core piece 20. The third core piece 21 is alternately provided with caulking portions 25 and caulking holes 24 each having a caulking projection 26 that is closely fitted into the caulking hole 24 of the third core piece 20. The third core piece 22 is also alternately provided with the caulking portions 25 and the caulking holes 24 having the caulking projections 26 that closely fit into the caulking holes 24 of the third core piece 21.

The third core piece 23 is alternately provided with a caulking portion 25 having a caulking projection 26 closely fitted into the caulking hole 24 of the third core piece 22 and a caulking hole 30 having a size into which the caulking projection 26 is loosely fitted. Is provided. Thus, the third laminated body 13 has a structure in which the third core pieces 20 to 23 are firmly caulked and laminated, but the third laminated bodies 13 that are adjacent to each other are not caulked and connected to each other. .

In order to manufacture 1 deformed iron core from the 1st-3rd connection laminated body 11a-13a manufactured continuously by each mold apparatus, the 1st-3rd laminated bodies 11-13 were taken out separately. 1A to 1C are shown. In the first stacked body 11, the uppermost first core piece (that is, every a piece of core pieces) 17 has the second lowermost part of the second stacked body 12 placed on the upper part. A caulking hole 24 and a caulking concave portion 27 into which the caulking protrusion 26 of the core piece 18 is closely fitted are provided. In addition, the uppermost second core piece (that is, every b pieces of core pieces) 19 of the second stacked body 12 is provided with a third core provided at the lowermost portion of the upper third stacked body 13. A caulking concave portion 27 into which the caulking projection 26 of the core piece 20 is closely fitted is formed. Accordingly, the first to third stacked bodies 11 to 13 are caulked and stacked.
Here, the first core piece 17 formed above the first laminated body 11, the second core piece 18 below the second laminated body 12, and the second upper part of the second laminated body 12. The core piece 19 and the third core piece 20 below the third laminated body 13 are connected to the caulking concave portion 27 (or the caulking hole 24) by caulking connection means using the caulking projection 26.

In the above-described embodiment, the case of the three laminated bodies 11 to 13 has been described. However, only the two laminated bodies 11 and 12 may be used, or four or more layers may be used. The number of core pieces constituting each laminate can be freely selected according to specifications.

(A) is a partially omitted cross-sectional view of the third stack, (B) is a partially omitted cross-sectional view of the second stack, (C) is a partially omitted cross-sectional view of the first stack, (D ) Is a partially omitted cross-sectional view of a deformed iron core manufactured by a method according to an embodiment of the present invention combining these. (A) is a partially omitted cross-sectional view of the third connected laminate, (B) is a partially omitted cross-sectional view of the second connected laminate, and (C) is a partially omitted cross-sectional view of the first connected laminate. It is. It is a top view of the deformed iron core manufactured by the method concerning one embodiment of the present invention. (A)-(C) are explanatory drawings of the manufacturing method of the deformed iron core which concerns on a prior art example.

10: Deformed core, 11: 1st laminated body, 11a: 1st connection laminated body, 12: 2nd laminated body, 12a: 2nd connection laminated body, 13: 3rd laminated body, 13a: 1st 3 connected laminates, 14 to 17: first core piece, 18, 19: second core piece, 20-23: third core piece, 24: caulking hole, 24a: axial hole, 25: caulking part , 26: caulking projection, 27: caulking recess, 28: bottom core piece, 29: caulking hole, 30: caulking hole, 32: bottom core piece

Claims (4)

A first laminated body obtained by caulking and laminating a first core pieces of the same shape, and b second second pieces that are caulked and laminated on the first laminated body and have different shapes from the first core pieces. A method for producing a deformed iron core having a second laminated body obtained by caulking and laminating core pieces,
A caulking concave portion or a caulking concave portion in which a caulking protrusion formed on the second core piece at the lowermost part of the second laminated body laminated on the first core piece is closely fitted to the first core piece every a pieces A caulking hole is formed, and the first core piece for each a and the first core piece disposed in the lower part thereof are caulked and laminated , and the first lowermost part of the first laminated body is the first Only a caulking hole is formed in the core piece, and the first laminated body is formed so that the first laminated body can be individually separated,
A caulking recess or a caulking hole into which the caulking projection of the second core piece placed on the upper part is loosely fitted is formed on the second core piece every b sheets, and the second core piece and the lower part thereof every b sheets The second core piece is caulked and laminated to form a second connected laminated body so that the second laminated body can be individually separated, and the first laminated body is separated from the first laminated body. A method for producing a deformed iron core, comprising: taking out a body, taking out the second laminated body from the second connected laminated body, and caulking them. The method of manufacturing a deformed iron core according to claim 1, wherein the first core piece and the first core pieces adjacent to each other in the upper and lower sides of the first laminated body and the second laminated body, the second core pieces, and the first and second laminated cores. Manufacturing of a deformed iron core characterized in that the positions of the caulking protrusions formed on the second core piece are different, and that the positions of the caulking protrusions are the same when viewed from above by one or two differences. Method. 3. The method of manufacturing a deformed iron core according to claim 1, wherein a caulking portion or a caulking portion including a caulking protrusion and an caulking concave portion on a core piece disposed in a lower portion is disposed above the second laminated body. Through the caulking connection means, a hole is formed, and a caulking portion including a caulking protrusion and a caulking recess that is closely fitted into the caulking recess or the caulking hole of the lower core piece is provided on the core piece that is disposed in the upper portion thereof. A method for producing a deformed iron core, wherein one or two or more laminated bodies having different caulking shapes are polymerized. 4. The method of manufacturing a deformed iron core according to claim 3, wherein the bottom of the connection laminate excluding the first connection laminate has the same shape as the core piece of the connection laminate, and is the lowest part of the connection laminate. A method of manufacturing a deformed iron core, comprising a bottom core piece provided with a caulking hole into which a caulking protrusion of the core piece is loosely fitted.

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