JP3316762B1 - Manufacturing method of iron core device - Google Patents

Abstract

A method for manufacturing a core device capable of improving magnetic performance and mechanical strength is provided. SOLUTION: A first core member in which a plurality of independent plate-shaped first core pieces are continuously arranged, and a second core member in which a plurality of independent plate-shaped second core pieces are continuously arranged. Alternately in the stacking direction, the position between each first core piece of the first core member and the second
The position between the second core pieces of the core member is shifted in the longitudinal direction,
A step of laminating so that edges adjacent to each other in the laminating direction of the core pieces are overlapped with each other, and a connecting means comprising a concave portion and a convex portion provided on the edge portion of each core piece, and a connection provided on the first core piece. And the connecting means provided on the second core piece are alternately stacked to form a rotation axis in the stacking direction, and the edges of the adjacent core pieces are rotatably connected.

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 core device constituting a main part of an electromagnetic device such as a motor or a transformer.

[0002]

2. Description of the Related Art As shown in FIGS. 58 and 59, for example, a core member of a conventional electric motor core device disclosed in Japanese Patent Application Laid-Open No. 9-191588 has a core piece 1a connected via a thin portion 1b. After laminating a predetermined number of sheets 1 and winding 2 by a winding machine (not shown) in the state of FIG. 59 to improve the winding property, each thin portion 1b is bent as shown in the figure. It is formed in a ring shape by making it.

[0003]

The conventional iron core device is constructed as described above, and the core pieces 1a opposed to each other through the surfaces to be joined when being formed in an annular shape, that is, the thin portions 1b. In addition, the end face of each edge of the core piece 1a located at both ends of the core member 1 is actually several μm to several tens μm because surface roughness and processing error occur at the time of press punching.
Since they are butted through a gap of about m, there is a problem that the magnetic resistance is increased by this gap and the magnetic performance of the iron core device is reduced.

[0004] Further, a coating is usually formed on the surface of the core member 1 constituting the iron core device, and the coating plays a role of inhibiting the passage of magnetic flux and suppressing eddy current loss. Since there is no coating on the end face, an eddy current is generated over the entire area in the stacking direction of the surfaces where the respective core pieces 1a are abutted, and this eddy current causes iron loss, thereby deteriorating magnetic performance.

[0005] In addition, since the holding force against the external force in the direction parallel to the surface is weak, the rigidity of the core device as a whole is also weak. In particular, in the case of a motor in which magnetic force is applied to the core device, there is a problem in strength. Was.

Further, since the thin portion 1b is formed in an annular shape by bending, it is difficult to obtain high precision mechanically.
In addition to the cracks occurring in b, the mechanical strength is lowered, and the cracks increase the magnetic path resistance and lower the magnetic performance.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and aims to improve magnetic performance by suppressing an increase in magnetic resistance and generation of eddy current, and to improve rigidity and mechanical accuracy. It is an object of the present invention to provide a method of manufacturing an iron core device capable of improving the quality.

[0008]

A method of manufacturing an iron core device according to the present invention comprises a first core member in which a plurality of independent plate-shaped first core pieces are continuously arranged, and an independent plate-shaped second core member. A second core member in which a plurality of core pieces are continuously arranged is alternately arranged in the laminating direction, and a position between the first core pieces of the first core member and a position between the second core pieces of the second core member are alternately arranged. A first core comprising a step of laminating so that edges adjacent to each other in the laminating direction of the core pieces overlap each other while being shifted in the longitudinal direction, and a connecting means comprising a concave portion and a convex portion provided at the edge portion of each core piece. The connecting means provided on one piece and the connecting means provided on the second core piece are alternately stacked to form a rotation axis in the stacking direction, and the adjacent core pieces are rotatably connected to each other. It is provided with the step of performing.

[0009] A method of manufacturing an iron core device according to the present invention includes:
The step of stacking each core piece and the step of connecting each core piece,
This is performed simultaneously by swaging.

[0010] A method of manufacturing an iron core device according to the present invention includes:
A step of unfolding each laminated core member by rotating each core piece by the connecting means, a step of applying a winding to each unfolded core member, and a winding by rotating each core piece by the connecting means The step of forming each of the core members provided with a ring shape into an annular shape or a rectangular shape.

[0011] A method of manufacturing an iron core device according to the present invention includes:
In the step of deploying each core member, a step of regulating the deployment is provided.

[0012] A method of manufacturing an iron core device according to the present invention includes:
In the step of forming each core member in an annular or rectangular shape,
The method includes a step of restricting the rotation of each core piece.

[0013] A method of manufacturing an iron core device according to the present invention includes:
A first core member in which a plurality of first core piece blocks in which a plurality of independent plate-shaped first core pieces are stacked are continuously arranged, and a second core in which a plurality of independent plate-shaped second core pieces are stacked. A second core member, in which a plurality of single blocks are continuously arranged, is alternately arranged in the stacking direction, and a position between the first core single blocks of the first core member and a position between the second core single blocks of the second core member. Is shifted in the longitudinal direction, the step of stacking so that the edges adjacent to each other in the stacking direction of each core piece block overlap, a connecting means comprising a concave portion and a convex portion provided at the edge portion of each core piece block. The connecting means provided on the first core piece block and the connecting means provided on the second core piece block are alternately stacked to form a rotation axis in the stacking direction, and the edge of each adjacent core piece block. And a step of connecting the two to each other in a rotatable manner.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a plan view showing a configuration of an iron core device of a motor according to Embodiment 1 of the present invention, FIG. 2 is a plan view showing a step of forming a core member shown in FIG. 1 by press punching, and FIG. FIG. 4 is a cross-sectional view showing the configuration of the connecting means of the core members formed through the steps, FIG. 4 is a plan view showing a state in which the core members formed through the steps shown in FIG. 2 are stacked, and FIG. 5 is shown in FIG. It is sectional drawing which shows the structure of the edge part of each core piece of the core member laminated | stacked in this way.

In the drawing, reference numeral 3 denotes a plate-shaped core piece made of a magnetic material, and a convex portion 3b as a connecting means is provided on the front and back surfaces of the edge at one end.
And a concave portion 3a, and the end surface 3c is formed in a convex arc shape centered on the center of the convex portion 3b and the concave portion 3a, and the end surface 3c of the adjacent core piece 3 is provided on the other end side.
A concave arc-shaped end face 3d that can be fitted to the end is formed. FIG.
As shown in FIG. 4, reference numeral 4 denotes a plurality of core pieces 3 each having an end face 3c, 3d.
The first core members are arranged continuously through the first core member. Reference numeral 5 denotes a second core member in which a plurality of core pieces 3 are continuously arranged via the end faces 3c and 3d. The core piece 3 of the first core member 4 has a connecting means (that is, a connecting mechanism) on the front and back surfaces of the edge on one end side.
The core 3 of the second core member 5 has a convex portion 3b and a concave portion 3a as coupling means (that is, a coupling mechanism) on the front and back surfaces of the other end side edge portion.
Are formed.

As shown in FIGS. 3, 4, and 5, the first core member 4 and the second core member 5 are alternately laminated, and
The position between the core pieces (that is, the position between the core end faces 3c and 3d) and the position between the core pieces of the second core member 5 (that is, the position between the core end faces 3c and 3d) are shifted in the longitudinal direction. The core pieces are stacked so that edges adjacent to each other in the stacking direction of the core pieces overlap with each other. Then, between the edges of the core pieces 3 adjacent to each other in the laminating direction, the protrusions 3 b and the recesses 3 a at one edge of the core piece 3 of the first core member 4 and the second core member 5
The protrusion 3b and the recess 3a at the other end of the core piece 3 are rotatably connected by fitting. FIG.
Reference numeral 6 denotes a winding wound around the magnetic pole teeth 3f (FIG. 4) of each core piece 3, and reference numeral 7 denotes a concave and a convex portion 3a, 3b of each core piece 3 of the laminated core members 4, 5. It is an iron core device formed in an annular shape by moving. In FIG. 1,
At the ends of the laminated core obtained by laminating the first core member 4 and the second core member 5 (joints between the annular bodies), connecting means (the convex portion 3b and the concave portion) are used to abut the ends. 3a) has been omitted.

Next, a method of manufacturing the iron core device according to the first embodiment configured as described above will be described. First, at a position indicated by an arrow T in FIG. 2, a convex portion and a concave portion which can be press-fitted on the front and back surfaces of the core member are formed by press punching at three places for each core piece. In this first stage, as shown in FIG.
b and the concave portion 3 a are formed, and two coupling concave and convex portions of the laminated core are formed at the center of the core piece 3. At the position shown by the arrow A, as a second stage of processing the first core member 4 at the portion where the uneven portion is formed at the stage of the arrow T, the portions shown by hatching in the figure are press-punched so that both end faces 3c, 3d and peripheral portions of both end faces 3c and 3d are formed. At the position indicated by the arrow B, as shown in a hatched portion in the figure, the both ends are pressed and punched as a second stage of processing the second core member 5 at the portion where the uneven portion is formed at the stage of the arrow T. Surfaces 3c, 3d and both end surfaces 3
The peripheral portions of c and 3d are formed.

Next, at the position shown by the arrow C in FIG. 2, the portion where the both end surfaces 3c and 3d are formed at the stage of the arrow A and the portion where both end surfaces 3c and 3d are formed at the stage of the arrow B are sequentially shown. By alternately punching the portions indicated by hatching in the figure, the first and second core members 4
5 are formed, and these two core members 4 and 5 are sequentially laminated in a mold.

At the position indicated by the arrow S, three through holes are formed for each core piece by a press punching operation at the same positions as the uneven portions formed at the stage of the arrow T. As a result, the core piece 3 serving as the uppermost layer of the laminated core has the protrusions 3
Three through holes 3e where b can be fitted are formed. Arrow B
At the position indicated by, as a second stage of processing the third core member 51 at the portion where the through-hole 3e was formed at the stage of the arrow S, the portions indicated by hatching in the figure are press-punched to thereby obtain both end faces 3c, 3d and peripheral portions of both end faces 3c and 3d are formed. At the position shown by the arrow C, the portion shown by hatching in the figure at the stage of the arrow B where the both end faces 3c and 3d are formed is press-punched to obtain a third position.
Is formed, and as the uppermost layer of the laminated core,
Laminated in the mold. For example, the thickness of a plate-shaped core piece is
At 0.5 mm, the number of laminated core pieces of the laminated core is 150.

In FIG. 2, the core pieces 3 at both ends of the first core member 4 and the second core member 5 are partially irregular at the edge with the central core piece 3. This is the core piece 3 at both ends
This is because the end portions of the laminated core in which the first core member 4 and the second core member 5 are laminated correspond to each other, and the end portions are easily brought into contact with each other. For this reason, in other embodiments, the core pieces at both ends of the laminated core are partially irregular with the center core piece.

The recesses 3a and the projections 3b and the through holes 3e and the projections 3b which face each other in the stacking direction of the core pieces 3 in the die are press-fitted together and are pressed and caulked.
Are integrated as shown in FIG. The magnetic pole teeth 3f of the core pieces 3 of the laminated core members 4, 5 and 51 are wound with the windings 6 (not shown) in the state shown in FIG. By rotating the convex portion 3b, the through hole 3e, and the convex portion 3b, the core device 7 is completed.

As described above, according to the first embodiment, the core pieces 3 are laminated so that the edges adjacent to each other in the laminating direction overlap each other. By increasing the surface area of the (edge), it is possible to suppress an increase in magnetoresistance and improve magnetic performance,
Also, the end faces 3c, 3d of the punched core pieces 3 are alternately shifted and separated by the overlapped dimension (that is, the end faces 3c, 3d of the core pieces 3 are not continuous), and are present in the same plane. , The generation of eddy currents is suppressed, iron loss is reduced, and magnetic performance can be improved.

Further, since the force applied in the laminating direction can be received at the alternately overlapped portions, the rigidity of the iron core device 7 can be increased and the mechanical strength can be improved.
Also, as shown in FIG. 5, the first core member and the second core member
When the sheets are alternately stacked, the magnetic path in the connection portion is formed in the stacking direction at the overlapping portion between the edges of the core pieces 3 adjacent to each other in the stacking direction, so that the magnetic performance can be improved.

As shown in FIG. 6, the first and second core members 4 and 5 are formed by a plurality of sheets, and for example, two to ten sheets may be alternately superposed on each other. When the core pieces 3 are rotated alternately by the connecting means (for example, the convex portion 3b and the concave portion 3a), the friction decreases as the number of the plural pieces increases. or,
When the laminated core formed by laminating the first core member and the second core member is formed into an annular shape and the ends thereof are connected to each other, the larger the number of pieces, the easier it is to fit the ends together, Productivity is improved.

Further, since the fitting portions of the concave portions 3a and the convex portions 3b are rotated so that the core members 4 and 5 are bent to form an annular shape, mechanical strength is reduced. In addition, since it is possible to make a plurality of diffraction bends and one end face 3c of each core piece 3 is formed in an arc shape centering on the rotation center of the connecting portion of the concave portion 3a and the convex portion 3b, The movement is facilitated, and workability such as winding work can be improved.

Although not shown, the recesses 3 of the core piece 3 are not shown.
If a gap is provided in the fitting portion of the protrusion a and the convex portion 3b, the accumulation of errors in the stacking direction generated at the time of swaging can be absorbed by this gap, and the rotation can be further facilitated. Also, as shown in FIG. 7, each recess 3a of the core piece 3 is formed to be long in the longitudinal direction of the core members 4 and 5, so that the fitted protrusions 3b are each elongated along the recess 3a. 8, the distance between the core pieces 3 can be increased as shown in FIG. 8, and the workability of the winding can be further improved. 7 and 8
The dash-dot line indicates that the core piece can move along the length by a dashed line.

Further, as shown in FIG. 9, the end faces 3c and 3d of each core piece 3 are made to have a polygonal cross section, for example, so that the concave and convex portions 3a and 3b (not shown) are rotated to form a core member. As shown in FIG. 10, when the parts 4 and 5 are bent, the corners of the end faces 3 c and 3 d bite and are deformed and fixed, so that the rigidity of the iron core device 7 is increased and the mechanical strength is improved. Can be.

Embodiment 2 FIG. 11 is a plan view showing a step of forming a core member of the iron core device according to Embodiment 2 of the present invention by press punching, FIG. 12 is a plan view showing a configuration of a first core member obtained in the step shown in FIG. FIG.
3 is a plan view showing the configuration of the second core member obtained in the step shown in FIG. 11, and FIGS. 14 and 15 show states in which the first and second core members in FIGS. 12 and 13 are alternately laminated, respectively. FIG. 16 is a plan view and a perspective view, and FIG. 16 is a plan view showing a part of the configuration of an iron core device according to Embodiment 2 of the present invention. The upper rightmost three core pieces 8 in FIG. 15 are not shown.

In the figure, reference numeral 8 denotes a plate-shaped core piece made of a magnetic material, and has a protrusion 8b on one end and a recess 8a which can be fitted with the protrusion 8b of the adjacent core piece 8 on the other end. These concave and convex portions 8a and 8b are detachable only in the stacking direction, that is, formed in an articulated shape, and a connecting means (that is, a connecting mechanism) for connecting a pair of edges of adjacent core pieces to each other. Make up. Reference numeral 9 denotes a plurality of core pieces 8 as shown in FIG.
Is a first core member continuously connected and arranged via the concave and convex portions 8a and 8b. Reference numeral 10 denotes a second core member in which a plurality of core pieces 8 are continuously connected and arranged via concave and convex portions 8a and 8b as shown in FIG. The core piece 8 of the first core member 9 has a projection 8b formed at one end and a recess 8a formed at the other end, and the core piece 8 of the second core member 10 has a projection 8b formed at the other end. A recess 8a is formed.

As shown in FIGS. 14 and 15, the first core member 9 and the second core member 10 are alternately laminated, and the positions between the respective core pieces of the first core member 9 (ie, adjacent core pieces) Between the convex portion 8b and the concave portion 8a) and the second core member 10
(I.e., the positions between the protruding portions 8b and the concave portions 8a of the adjacent core pieces) are shifted in the longitudinal direction, and the adjacent edges in the stacking direction of the respective core pieces are stacked so as to overlap each other. ing. Reference numeral 11 denotes an iron core device formed in an annular shape by rotating the concave and convex portions 8a and 8b of each core piece 8 and bending both core members 9 and 10.

Next, a method of manufacturing the iron core device according to the second embodiment configured as described above will be described. FIG.
At a position indicated by an arrow T in FIG. 1, a convex portion and a concave portion which can be press-fitted on the front and back surfaces of the core member are formed by press punching operation at two places for each core piece. In this first stage, as shown in FIG. 15, two concave and convex portions for coupling of the laminated core are formed at the central portion (magnetic pole teeth) of the core piece 8. At the position indicated by the arrow A, a cut 12 of the outer shape of the concave and convex portions 8a and 8b is made as a second stage of processing the first core member 9 at the portion where the uneven portion is formed at the stage of the arrow T. Next, at the position shown by the arrow C, the part shown by hatching in the figure as a third step is press-punched at the part where the cut 12 was made at the step of the arrow A, thereby removing the peripheral parts of the concave and convex parts 8a and 8b. Form. Further, at a position indicated by an arrow B, as a second step of processing the second core member 10 at a portion where the uneven portion is formed at the step of the arrow T,
Cuts 13 of the outer shape of the concave and convex portions 8a and 8b are made. Next, at the position shown by the arrow D, the portion shown by the hatching in the figure as a third stage is press-punched at the portion where the cut 13 was made at the stage of the arrow B, so that the peripheral portions of the concave and convex portions 8a and 8b are removed. Form.

Next, at the position indicated by the arrow E in FIG. 11, the concave and convex portions 8a and 8b are formed at the position indicated by the arrow C, and the concave and convex portions 8a are formed at the position indicated by the arrow D. , 8b are punched out by pressing the portions indicated by hatching in the figure alternately, thereby forming the first and second core members 9, 10 respectively.
Are formed, and these two core members 9 and 10 are sequentially laminated in a mold.

At the position indicated by the arrow S, two through holes are formed for each core piece at the same positions as the concave and convex portions formed at the stage of the arrow T by a press punching operation. As a result, the core piece 8, which is the uppermost layer of the laminated core, has two through holes into which the protrusions can be fitted. At the position shown by the arrow B, at the portion where the through hole was formed at the stage of the arrow S,
As a second stage of processing the third core member 52 (FIG. 15), cuts 13 of the outer shapes of the concave and convex portions 8a and 8b are made. Next, at the position shown by the arrow D, the portion shown by the hatching in the figure as a third stage is press-punched at the portion where the cut 13 was made at the stage of the arrow B, so that the peripheral portions of the concave and convex portions 8a and 8b are removed. Form. At the position indicated by arrow E, the third core member 52 is formed by press-punching the portion indicated by hatching in the portion where the concave and convex portions 8a and 8b are formed at the stage of arrow D,
It is laminated in a mold as the uppermost layer of the laminated core.

The concave and convex portions (of the magnetic pole teeth) facing each other in the laminating direction of the core pieces 8 in the mold are press-fitted together, and are pressed together to integrate the laminated core. The magnetic pole teeth 8f of the core pieces 3 of the laminated core members 9, 10 and 52 are wound (not shown) in the state shown in FIG. 15 and then concave and convex as shown in FIG. By rotating the portions 8a, 8b, the coil members 9, 10,
The core device 1 is formed in an annular shape by bending
1 is completed.

As described above, according to the second embodiment, the concave and convex portions 8a and the convex portions 8b formed in an articulated shape are formed at both ends of the core piece 8, and the concave and convex portions 8a and 8b are provided in the respective core pieces 8a and 8b. And by rotating the concave and convex portions 8a, 8b, the core members 9, 10, 52 are bent, so that the rotation is easy and the assembly is, of course, easy. Accuracy can be improved.

Embodiment 3 FIG. 17 is an exploded perspective view showing a configuration of a main part of an iron core device according to Embodiment 3 of the present invention, and FIG. 18 shows a configuration different from FIG. 17 of a main part of an iron core device according to Embodiment 3 of the present invention. Plan view, FIG. 19
FIG. 19 is a plan view showing a state different from that in FIG. 18 of a main part of the core device shown in FIG. 18.

In the drawing, reference numeral 14 denotes a plate-shaped core piece made of a magnetic material, and a hole 14a penetrating through one end side edge is formed.
The end face has a convex arc-shaped end face 14b centered on the center of the hole 14a, and the other end side has the end face 1 of the adjacent core piece 14.
A concave arc-shaped end face 14c that can be fitted to 4b is formed. 15 is a plurality of core pieces 14 each end face 14b,
The first core members are continuously arranged through the first core member 14c. Reference numeral 16 denotes a second core member in which a plurality of core pieces 14 are continuously arranged via the end surfaces 14b and 14c. The core piece 14 of the first core member 15 has a hole 14
a is formed, and the core piece 14 of the second core member 16 is formed with a hole 14a penetrating the other end side edge.

The first core member 15 and the second core member 16 are alternately laminated, and the position between the core pieces of the first core member 15 (that is, the position between the core end faces 14b and 14c) and the second core member The position between the core pieces of the member 16 (ie, the position between the core end faces 14b and 14c) is shifted in the longitudinal direction,
The core pieces are stacked such that edges adjacent to each other in the stacking direction overlap each other. Numeral 17 penetrates the holes 14a of the laminated core pieces 14 and rotatably connects the core pieces 14 (that is, the core pieces of the first core member and the second core member adjacent to each other in the laminating direction). A crimped pin member is provided to prevent the falling off. In addition, the pin member 17 may be configured by a bolt and a nut. The through-hole 14a of the core piece of the first core member 15 adjacent to the lamination direction, the through-hole 14a of the core piece of the second core member 16, and the pin member 17
And constitute a coupling means (that is, a coupling mechanism). Since the connecting portion is rotated via the pin member 17 and the laminated core members 15 and 16 are bent in an annular shape to constitute the iron core device, the rotation is further facilitated and the assembling accuracy is improved. Can be improved.

Note that, as shown in FIGS.
The outer shape of the hole 14a and the pin member 17 is, for example, polygonal, and when the core members 15 and 16 are bent in an annular shape, the corners of the pin member 17 are formed as shown in FIG.
If it is made to bite into the inner surface of a and be fixed, the rigidity of the iron core device can be increased and the mechanical strength can be improved.

Embodiment 4 FIG. FIG. 20 shows a configuration of a main part of an iron core device according to Embodiment 4 of the present invention.
Is a cross-sectional view showing a state in which the edges of the core pieces at the ends of the laminated core face each other, FIG. 21B is a cross-sectional view showing a state in which the ends of the laminated core are abutted and joined, and FIG. 20A is a cross-sectional view showing a configuration of a main part of an iron core device according to Embodiment 4 of the present invention which is different from FIG. 20, and FIG. (B)
FIG. 4 is a cross-sectional view showing a state where the ends of the laminated core are in contact with each other. FIGS. 20 and 21 show a device relating to the contact of the end of the laminated core when each core piece of the laminated core is rotated to form an annular shape.

In the drawing, reference numeral 18 denotes a laminated core in which the edges of core pieces 18a opposed to each other in the laminating direction are successively overlapped in the laminating direction as shown in FIG. 20, and 19 is a laminated core as shown in FIG. The laminated cores are laminated such that the edges of the opposing core pieces 19a form a V-shape.

As described above, according to the fourth embodiment, since the end portions of the laminated cores are sequentially laminated so as to be overlapped in a stepwise manner, when they are bent in an annular shape and the two end portions are brought into contact with each other, they are opposed to each other. Because there is no restriction on the movement of the end of the laminated core in the laminating direction, even if one of the cores becomes caught at the time of bending, it can be easily released by releasing in the laminating direction and smoothly Can be bent and abutted, and assembling workability can be improved. Furthermore, since the core pieces of the laminated core ends are surface-bonded, the magnetic resistance can be reduced even at the laminated core ends.

Since the end portions of the laminated core are laminated so as to form a V-shape, the core piece 19a becomes a V-shaped apex when bent into an annular shape and joined at both ends. Because the position is regulated at the center in the direction, even if the edges of any of the core pieces 19a are temporarily caught at the time of bending, by vibrating in the laminating direction, the caught is easily eliminated and smoothly. It can be folded and overlapped, and the assembling workability can be improved. further,
Since the core pieces at the ends of the laminated core are surface-bonded, the magnetic resistance can be reduced even at the ends of the laminated core.

Embodiment 5 FIG. 22 and 23 are a plan view and a sectional view showing a method of assembling the main parts of the iron core device according to Embodiment 5 of the present invention. In the figure, 20,
Reference numerals 21 denote first and second core members which are sequentially laminated. At the corresponding positions of the edges of the core pieces 22 and 23 at both ends of the laminated core, holes 22a as projections to be detachably fitted and projections are provided. Portions 23a are respectively formed, and the core pieces 23 of the second core member 21 are hatched in FIG. FIG. 23A is a cross-sectional view taken in the direction of the arrow at the position of the dashed line in FIGS. 22A, 22B, 22C and 22D.
(B), (C), and (D) respectively.

Next, a method of assembling an iron core device by bending the laminated core having the above-described configuration and having both ends in contact with each other will be described. First, FIG.
23A, the core pieces 22, 2 of the first and second core members 20, 21 at both ends of the laminated core.
3 is rotated around a connecting portion (not shown) of the connecting means (for example, the concave portion 3a and the convex portion 3b in FIG. 3), and one end side is turned as shown in FIGS. 22 (B) and 23 (B). The edge of the core piece 23 of the even-numbered layer is shifted in the direction indicated by the arrow in the drawing, and the edge of the core piece 22 of the odd-numbered layer is shifted on the other end side.

Then, the fitted hole 22a and the convex portion 23a are detached, and each convex portion 23a moves to a position where there is no hole 22a. Of the hole. Then, FIG.
As shown in FIG. 2 (C) and FIG. 23 (C), both ends of the laminated core are drawn and inserted into the gaps so that the edges of the core pieces 22 and 23 overlap each other.
In the state shown in FIG. 3 (D), the core device is formed in an annular shape, and the assembly is completed.

As described above, according to Embodiment 5, the end portions of the first and second core members 20 and 21 to be laminated are detachably provided at the positions corresponding to the edges of the core pieces 22 and 23. Forming a fitting hole 22a and a convex portion 23a, respectively,
At the time of assembling, the gap between the core pieces 22 and 23 is expanded by detaching the holes 22a and the protrusions 23a, so that the end portions of the laminated cores of the first and second core members 20 and 21 contact each other. The contact and joining are facilitated, and the assembling workability can be improved. Furthermore, since the core pieces of the laminated core ends are surface-bonded, the magnetic resistance can be reduced even at the laminated core ends.

Embodiment 6 FIG. FIG. 24 is a front view showing the configuration of an iron core device according to Embodiment 6 of the present invention, and FIG. 25 is a plan view showing material removal for forming the core member shown in FIG. 24 by press punching. In the figure, reference numeral 24 denotes a magnetic pole taste 24 around which a coil (not shown) is wound at the center.
a is a pair of first core members protrudingly provided, and 25 is a pair of second core members rotatably connected at the center. The first core member 24 is laminated to form a second laminated core. A first laminated core in which the second core members 25 are laminated is formed. The first laminated core on which the second core member 25 is laminated is, for example, the same as the laminated core formed in Embodiment 1 and having two core pieces per layer.
The first laminated core is rotated by connecting means, and the first laminated core and the second laminated core are combined and abutted and joined to form the core device 26 connected in a ring shape.

As described above, according to the sixth embodiment, since the core device 26 is configured by connecting the divided first laminated core and the second laminated core, each core member 24 is formed by press punching. In the case of removing the material 25, for example, as shown in FIG. 25, each of the core members 24 and 25 can be arranged in the minimum necessary space, so that the yield of the material can be improved.

Embodiment 7 FIG. FIG. 26 is a plan view of a laminated core before assembling an iron core according to Embodiment 7 of the present invention.
FIG. 27 is a plan view showing an iron core device assembled using the laminated core of FIG. 26. In FIG. 26, 93 is a first laminated core, 94 is a second laminated core, and 95 is a third laminated core.
These are formed by dividing the laminated core of the iron core device in FIG. 1 of the first embodiment into three parts, and are formed similarly to the laminated core of FIG. That is, each laminated core is
A first core member in which a plurality of plate-shaped first core pieces are continuously arranged; and a second core member in which a plurality of plate-shaped second core pieces are continuously arranged.
The core members are alternately arranged in the laminating direction, and the positions between the first core pieces of the first core member and the positions between the second core pieces of the second core member are shifted in the longitudinal direction. Are connected so that edges adjacent to each other in the stacking direction overlap each other, and connecting means for connecting edges of adjacent core pieces are provided. At the ends 96 and 97 of the respective laminated cores, the connecting means (the convex portions 3b and the concave portions 3a) are omitted in order to combine and abut the ends 96 and 97.

In the case of FIG. 1, one laminated core as a whole is rotated by each core piece to form an annular shape, thereby forming an iron core device. In the case of FIGS. (Not shown), each core piece of the laminated core is rotated by the connecting means, and the first laminated core, the second laminated core, and the third laminated core are combined to form an annular shape. 98
(FIG. 27). In FIG. 27, 99, 100,
Reference numeral 101 denotes a connecting portion that connects the ends of the laminated cores 93, 94, and 95 to each other. As described above, when the laminated core is divided and assembled, the laminated core can be divided into a size that can be easily worked, so that workability is improved. Embodiment 8 FIG. FIG. 28 is a plan view showing a configuration of an iron core device according to Embodiment 8 of the present invention, FIG. 29 is a plan view showing a configuration of a core member shown in FIG. 28, and FIG.
FIG. 30 is a plan view showing a main part having a configuration different from that of FIG.
32 is a plan view showing a main part of a configuration in which the core member shown in FIG. 32 is formed in an annular shape, FIG. 32 is a plan view showing a main part of the core member having a configuration further different from FIG. 29, and FIG. 33 is a core shown in FIG. It is a top view which shows the principal part of the structure of the state in which the member was formed in an annular shape.

In the figure, the same parts as those in the first embodiment are denoted by the same reference numerals, and the description is omitted. 27,
Reference numeral 28 denotes an abutting surface serving as a rotation restricting means formed by abutting the core members 4 and 5 from the respective end surfaces 3c and 3d of each core piece 3 in a state where the core members 4 and 5 are formed in an annular shape, and protruding in a direction blocking the rotation. The core members 4 and 5 are formed in an annular shape with the respective contact surfaces 27 and 28 in contact with each other, and the iron core device 7 is configured as shown in FIG. The respective contact surfaces 27 and 28 are formed on the first core member or the second core member, that is, on the end surfaces 3c and 3d of the same layer.

As described above, according to the eighth embodiment, in a state where the two core members 4 and 5 are formed in an annular shape on the respective end surfaces 3 c and 3 d of the respective core pieces 3, the abutting surfaces 27 abutting on each other. ,
28 are formed so as to restrict the rotation of the connecting portion of each core piece 3, positioning in the case of forming an annular shape becomes easy, and assembling workability can be improved.

As shown in FIGS. 30 and 32, one abutment surface 29, 31 of each core piece 3 is formed in a deformable shape, and is positioned in a jig to form an annular shape. As shown in FIG. 33, one contact surface 29, 31
If it is made to bite into the other contact surfaces 30 and 32, it is possible to receive a radial force, so that it is possible to obtain an iron core device particularly suitable for an electric motor that requires mechanical strength in the radial direction. it can.

Also, as shown in FIG. 30 and FIG. 32, at positions different from the positions where the respective contact surfaces 29, 30, 31, 32 of the respective core pieces 3 are formed, a direction opposite to the direction in which they are bent in a ring shape. If the contact surfaces 33 and 34 are formed in the direction that blocks the rotation, and the rotation of the connecting portion of each core piece 3 in the reverse direction is regulated, the core member warps at the time of winding the core, making the operation difficult. Can be prevented, and assembling workability can be improved.

Further, as shown in FIGS. 34 and 35, engaging projections 33a, 34a, 35a, 36a are respectively formed on a part of each contact surface 33, 34, 35, 36 of each core piece 3. In a state where the respective contact surfaces 33, 34 and 35, 36 are in contact with each other, the respective engagement protrusions 33a, 34a, 35
If the posture of the core member can be temporarily fixed in that state by engaging the a and 36a with each other, the winding operation of the core and the bending operation of the core member are facilitated, and the assembling workability is improved. Can be achieved.

Embodiment 9 FIG. FIG. 36 is an exploded perspective view showing a configuration of an iron core device according to Embodiment 9 of the present invention. In the figure, the same parts as those in the first embodiment are denoted by the same reference numerals, and description thereof will be omitted. 37, 38,
Numeral 39 denotes a cylindrical insulating bobbin having flange portions 37a, 38a, 39a formed at both ends, respectively. The insulating bobbin 37 is formed by a pair of vertically divided divided pieces 37b, 3b.
In FIG. 7B, the insulating bobbin 38 is constituted by a pair of divided pieces 38b, 38b divided into right and left. The insulating bobbin 39 is formed integrally with the laminated core 18. Each of the insulating bobbins 37, 38, and 39 integrally holds the core pieces 3, which are disposed so as to face each other in the laminating direction of the core members 4, 5 laminated by the cylindrical body. I have.

As described above, according to the ninth embodiment, the core pieces 3 disposed opposite to each other in the stacking direction of the core members 4 and 5 to be stacked are connected to each other by the insulating bobbins 37 and 38. 3
Since the core pieces 3 are integrally held, the core pieces 3 can be integrated without giving any influence such as distortion, so that an increase in magnetic resistance can be suppressed and magnetic performance can be improved. The above description is based on three different types of insulating bobbins 3.
Although the description has been made of the case where 7, 38, and 39 are used, for example, a configuration using only the insulating bobbin 37 may be used, and it goes without saying that the same effect as described above can be exerted.

Although not described in the first to eighth embodiments, each core member is bent in an annular shape by rotating the connecting portion of each core piece, and then each connecting portion is welded. When fixed, rigidity is improved, and an iron core device having excellent mechanical strength can be obtained.

In each of the first to ninth embodiments, the case of the iron core device applied to the electric motor has been described. However, the present invention is not limited to this. For example, as shown in FIGS. 37 and 38, a laminated core is formed by changing the core piece with the magnetic pole teeth in the first embodiment to a linear core piece 40 (with no magnetic pole teeth). After applying the winding 41 to the laminated core, the connecting portion is rotated to form an annular or rectangular iron core device. It is needless to say that the present invention may be applied to an iron core device of a transformer such as a zero-phase current transformer formed as described above, and the same effect as described above can be exerted. In the case of an iron core device for a current transformer, it is desirable that the abutting joints at both ends of the laminated core be abuttingly joined at surfaces adjacent to each other in the laminating direction to reduce the magnetic resistance also at the end of the laminated core. Embodiment 10 FIG.

FIG. 39 is a plan view of a laminated core before assembling the core according to the tenth embodiment of the present invention, and FIG. 40 is a plan view showing an iron core device assembled using the laminated core of FIG. In FIG. 39, reference numeral 111 denotes a first laminated core, and 112 denotes a second laminated core. These are shown in FIG.
Is formed by dividing the laminated core into two parts,
It is formed similarly to the laminated core of FIG. That is,
The first laminated core 111 includes a first core member in which three plate-shaped first core pieces (having no magnetic pole teeth) are continuously arranged, and a plate-shaped second core piece (having magnetic pole teeth). Are alternately arranged in the stacking direction, and the position between each first core piece of the first core member and each second core piece of the second core member are alternately arranged in the stacking direction. The position is shifted in the longitudinal direction, and the adjacent edge portions in the laminating direction of the core pieces are stacked so as to overlap with each other, and a connecting means for connecting the edge portions of the adjacent core pieces is provided. . The ends 113 and 114 of the first laminated core are connected to the first core piece of the first core member and the second core piece.
The second core piece of the core member has irregularities.

The second laminated core has a first core member composed of one plate-shaped first core piece (having no magnetic pole teeth) and a single plate-shaped second core piece (having magnetic pole teeth). Not formed) alternately in the stacking direction,
The first core member and the second core member are stacked while being shifted in the longitudinal direction. The ends 113 and 114 of the second laminated core are uneven between the first core piece of the first core member and the second core piece of the second core member. End 11 of first and second laminated cores
In 3 and 114, the connecting means (the convex portion 3b and the concave portion 3a) are omitted in order to insert the ends 113 and 114 into each other and to combine and abut them.

In the case of FIG. 37, one laminated core as a whole is rotated by each core piece to form a rectangular shape to form an iron core device. In the case of FIGS. (Not shown)
Is performed, each core piece of the first laminated core is rotated by the connecting means, and the end portions 113 and 11 of the first laminated core and the second laminated core are rotated.
4 are formed in a rectangular shape by inserting and combining the concavities and convexities to form a transformer core device 115 (FIG. 40). As described above, when the laminated core is divided and assembled, the laminated core can be divided into a size that can be easily worked, so that workability is improved.

Embodiment 11 FIG. FIG. 41 is a front view showing a configuration of a core device of a zero-phase current transformer according to Embodiment 11 of the present invention, FIG. 42 is a plan view showing a process of assembling a core member of the core device in FIG. 41, and FIG. FIG. 44 is an operation view showing a step of rotating and bending the connecting means of the core member, and FIG. 44 is a view for explaining the principle of the present invention.

In the figure, reference numeral 51 denotes a first core piece A, 52 which is made of a plate-shaped magnetic material and has a convex portion 51b and a concave portion 51a as connecting means formed on the front and rear surfaces at one end edge. Similar to A51, a first core piece B made of a plate-shaped magnetic material has a cutout portion 52a around which a winding (not shown) is wound, and a front edge and a rear edge at one end. A convex portion 52c and a concave portion 52b are formed as connecting means. The first core member 53 is formed by continuously arranging a plurality of first core pieces A and first core pieces B with a gap therebetween. 54 is a plate-shaped magnetic material, and on the other side edge front and back,
The second core pieces A and 55 in which the convex portions 54b and the concave portions 54a as connecting means are formed are second core pieces B made of a plate-like magnetic material similarly to the second core piece A54, and are wound around the body. A notch portion 55a around which a wire (not shown) is wound is formed, and a convex portion 55c and a concave portion 55b as connecting means are formed on the front and rear surfaces of the other edge. The second core member 56 is formed by continuously arranging a plurality of second core pieces A and second core pieces B with a gap therebetween.

Each of the first core pieces A51 and B52 has
The convex portions 51a, 51b, 52b, 52c and the concave portions and convex portions 54a, 54b, 55 of the second core pieces A54, B55.
As shown in FIG. 44A, the positions of b and 55c are from the intersection 60 between the center lines 54x and 55x in the width direction of the core pieces A54 (51) and B55 (52),
A position 6 on the bisector 61 at an angle of 55x, which is remote outward (ie, opposite to the center side of the core device of the zero-phase current transformer);
2 is provided. The notches 52a, 55a
The center lines in the width direction of the core pieces B52 and B55 are the same as the centerlines when there are no cutouts 52a and 55a.

As shown in FIG. 42 (B), the first core member 53 and the second core member 56 are alternately laminated, and the position between the first core pieces A51 and B52 of the first core member 53 and the second 2
The positions of the core members 56 between the second core pieces A54 and B55 are shifted in the longitudinal direction, and the core pieces are stacked so that the edges adjacent to each other in the stacking direction of the core pieces overlap. Then, the first core member 53 is formed between the edges of the core pieces adjacent to each other in the laminating direction.
The protrusions 51b, 52c and the recesses 51a, 52b on the one end side of the core piece of the first embodiment and the protrusions 54b, 55c and the recesses 54a, 55b on the other end side of the core piece of the second core member 56 fit together. As a result, it is connected rotatably.

The first core member 53 and the second core member 56 are sequentially formed by press punching.
At the stage of lamination, both core pieces A51, B52, A54, B
The concave and convex portions opposing each other in the laminating direction of 55 are fitted together, and at the position shown by an arrow in FIG. Then, after winding (not shown) is applied to portions corresponding to the cutout portions 52a and 55a of the core pieces B52 and B55, the fitted concave and convex portions are rotated as shown in FIG. The core device 58 is completed by being bent and formed into a rectangular shape as shown in FIG.

According to the iron core device 58 of the eleventh embodiment configured as described above, each of the first core pieces A51, B52 of the first core member 53 and each of the second core pieces A54, of the second core member 56, As shown in FIG. 44 (A), the connecting portion of B55, that is, the position of each concave and convex portion, is set to each core piece A54 (5
1), each center line 54x, 55 in the width direction of B55 (52)
A point 62 is set at a position 62 away from the intersection point 60 between x on the bisector 61 at an angle formed by both center lines 54x and 55x (ie, on the opposite side to the center side of the core device of the zero-phase current transformer). In the state where the iron core device 58 is configured,
Although the end faces 54c and 55e of both core pieces A54 and B55 are in contact with each other and are in sufficient contact, FIG.
As shown in (A), both core pieces A54 (51), B55
In the state where (52) is press-punched, appropriate gaps 59 can be formed, so that the press-punching operation can be facilitated without lowering the magnetic performance.

On the other hand, as shown in FIG. 44B, when the positions of the concave and convex portions are set at the same position as the intersection 60 between the center lines 54x and 55x, both core pieces A54 (51) and B5
Even when 5 (52) is press-punched, the end faces 54c and 55e of both core pieces A54 and B55 are in contact with each other, so that the magnetic performance is not reduced, but the press-punching operation is difficult. Become.

Further, as shown in FIG. 44 (C), the positions of the concave and convex portions are aligned on the center line 55x by the two center lines 54x, 55x.
In the state where both core pieces A54 (51) and B55 (52) are press-punched, a gap is formed between the end faces 54c and 55e, so that press-punching is easy. Although next be implemented, the yield of the material for both the core piece A54, B55 can step y ₁ deteriorates. Incidentally, the two although bisector is desirable to set the intersection 60 at a position 62 spaced outwardly over at 61, if an acceptable level difference y _1, even apart min can permit the step y ₁ from the bisector 61 It is feasible.

Further, as shown in FIG. 44 (D), the positions of the concave portions and the convex portions are aligned on the center line 55x by the two center lines 54.
When the position 64 is set inside the intersection 60 of x and 55x (that is, on the center side of the iron core device of the zero-phase current transformer), in a state where both core pieces A54 (51) and B55 (52) are press-punched, , FIG 44 (C) to the definitive when Equally the material yield can step y ₁ both core pieces becomes poor, of course, for the end surfaces 54c, to each other 55e may overlap only y _2, the press punching Problems such as being impossible occur.

Embodiment 12 FIG. 45 is a front view showing a configuration of an electric motor core device according to Embodiment 12 of the present invention, FIG. 46 is a plan view showing steps of an assembling method of a core member of the iron device in FIG. 45, and FIG. It is a top view which shows the structure of the principal part of a member.

In the drawing, reference numeral 71 denotes a plate-shaped core piece made of a magnetic material, and a concave portion 7 serving as a connecting means is provided on the front and back surfaces at one end side edge.
1a and the projection 71b are formed and the end face 7
1c is formed in a convex arc shape, and the adjacent core piece 7 is provided on the other end side.
A concave arc-shaped end surface 71d that can be fitted to the first end surface 71c is formed, and a magnetic pole tooth 71e around which a winding (not shown) is wound protrudes inward from the center. The first core member 72 is formed by continuously arranging a plurality of core pieces 71 with a gap therebetween. Reference numeral 73 denotes a plate-shaped core piece made of a magnetic material. A concave portion 73a and a convex portion 73b as connecting means are formed on the front and rear surfaces of the other end side edge, and an end surface 73c is formed in a convex arc shape. Has a concave arcuate end face 73 that can be fitted to the end face 73c of the adjacent core piece 73.
d is formed, and a magnetic pole tooth 73e around which a winding (not shown) is wound protrudes inward from the center. The second core member 74 is formed by continuously arranging a plurality of core pieces 73 with a gap therebetween.

The positions of the concave portions 71a and 73a and the convex portions 71b and 73b of each of the core pieces 71 and 73 correspond to the adjacent core pieces 73 in the arrangement direction as shown in FIG.
(71), 73 (71), the center line 73 in the width direction
x, 73x from the intersection 74 between the two center lines 73x, 7
It is provided at a position 76 on the bisector 75 of an angle formed by 3x, which is located outwardly (ie, on the side opposite to the center side of the core device of the electric motor). The center line 73x in the width direction of the core piece 73 is slightly different between the end portion and the center portion of the core piece 73, but does not substantially pose a problem.

As shown in FIG. 46A, the first core member 72 and the second core member 74 are alternately laminated, and the position between the respective core pieces 71, 71 of the first core member 72 and the second core member The position between the core pieces 73, 73 of the member 74 is shifted in the longitudinal direction, and the core pieces are stacked so that the edges adjacent to each other in the stacking direction of the core pieces overlap. Then, between the edges of the core pieces adjacent to each other in the laminating direction, the protrusion 71b and the recess 71a at one edge of the core piece of the first core member 72, and the other edge of the core piece of the second core member 74. Convex portion 73b and concave portion 73
a is rotatably connected by fitting.

The first core member 72 and the second core member 74 are sequentially formed by press punching.
At the stage of lamination, the respective concave and convex portions facing each other in the laminating direction of the two core pieces 71 and 74 are fitted with each other, and the core pieces are punched and integrated at a central position of the core pieces to obtain a diagram. A laminated core 77 shown in FIG. Then, after a winding (not shown) is applied to the magnetic pole teeth 71e, each of the fitted concave and convex portions is bent by being rotated, thereby forming an annular shape as shown in FIG. The iron core device 78 is completed.

As described above, according to the twelfth embodiment,
As shown in FIG. 47A, the positions of the concave portions and the convex portions of each of the core pieces 71 and 73 are changed to the core pieces 73 (7
1), 73 (71), 73x, 7 in the width direction.
Since it is provided at a position 76 on the bisector 75 of the angle formed by the center lines 73x and 73x from the intersection 74 between the 3x and the outside (that is, on the side opposite to the center side of the iron core device of the electric motor), the position 76 is shown in FIG. In the state where the iron core device 78 is configured as shown in FIG. 47 (A), although the end faces 73c and 73d of the adjacent core pieces 73 and 73 are in contact with each other and are in sufficient contact, FIG. ), Each core piece 73, 7
In a state where 3 is press-punched, an appropriate gap 79 can be formed, so that the press-punching operation can be facilitated without lowering the magnetic performance.

Also, the recesses 71a, 7 of the core pieces 71, 73
FIG. 47A shows the positions of 3a and the convex portions 71b and 73b.
In the state where both core pieces 73 and 73 are press-punched, when the center line (the center line of the left core as viewed in the drawing) 73x is set to the right 80 from the bisector 75, 73c, although press-punching a gap 79 is formed between 73d can be carried out becomes easy and the yield of the material for both the core pieces 73, 73 can step y ₁ as FIG. 44 (C) is deteriorated. Incidentally, the two although bisector is desirable to set to a position 76 spaced outwardly from the intersection point 74 at 75 over, if acceptable stepped y _1, even apart min can permit the step y ₁ from the bisector 75 It is feasible.

FIG. 48 is a plan view showing a main part of a core piece having a different connection portion between core pieces adjacent in the arrangement direction. 47 denote the corresponding parts in FIG. 47. FIG. 48A shows that the other end surface of the core piece 73 is formed in a straight line with the convex arc-shaped portion,
When the end face on one end side is formed in a straight line with the concave arc-shaped portion and is turned at the position 76 of the connecting means to form an annular core device, both end faces abut on the whole. The figure shows the contact state. FIG. 48 (B) shows that the other end surface of the core piece 73 is formed in a convex shape with two straight lines, the one end surface is formed in a straight line,
When the joint is rotated at the position 76 of the connecting means to form an annular core device, both end faces abut against each other. The figure shows the contact state.

In the eleventh and twelfth embodiments, the connecting means may be holes and pin members as in the third embodiment, instead of the concave and convex parts as the connecting means. In each of the eleventh and twelfth embodiments, the case of the zero-phase current transformer and the iron core device of the electric motor has been described. However, the present invention is not limited to this, and the present invention is not limited to this. It goes without saying that the same effect can be exerted even when applied.

Embodiment 13 FIG. FIGS. 49 to 57 are perspective views showing an iron core device suitable for a medium-sized electric motor according to Embodiment 13 of the present invention in the order of manufacturing steps. FIG. 49 is a perspective view of a core piece block showing a core pressing step. FIG.
Reference numeral 0 is a perspective view in which core piece blocks indicating a shaft connecting step are stacked in a line. FIG. 51 is an exploded perspective view of three teeth showing a stacking arrangement process. FIG. 52 is an exploded perspective view of the 3 teeth showing the 3 tooth temporary fixing step. FIG. 53 is an exploded perspective view of three teeth showing an insulating piece assembling step. FIG. 54 is a perspective view of three teeth showing a winding step. FIG.
It is a perspective view which shows a tooth block fixing process. FIG.
6 is a development view of the iron core device showing the entire circumference connecting process. FIG.
FIG. 7 is a perspective view of the iron core device showing a connection, a varnish, and a shrink fitting process.

In the iron core device of the thirteenth embodiment, in FIG. 17 of the third embodiment, a plurality of core pieces 14 are laminated to form a core piece block. Therefore, the first core member also has a single-layer structure. Instead, it is formed of a plurality of layers (for example, 100 sheets). Also, the second core member is not formed of a single layer but is formed of a plurality of layers. Hereinafter, the manufacturing steps will be described in order. In FIG. 49 (A), reference numeral 81 denotes a plate-shaped core piece made of a magnetic material. A hole 81a which is a part of a connecting means is formed at one end side edge, and the end face is formed in a convex arc shape. .
On the other end side of the core piece 81, a concave arc-shaped end face that can be fitted to an end face of an adjacent core piece is formed. Furthermore, the core piece 8
1 has a magnetic pole tooth 81b and a hole 81c. The core pieces 81 have a thickness of, for example, 0.5 mm and are formed by press punching, and about 100 pieces are laminated to form one first core piece block 82. The space between the core pieces of the first core piece block 82 is integrated, for example, by crimping with a concave convex part (not shown).

Therefore, the first core piece block 82
Has a hole 82a which becomes a part of the connecting means at one end side edge, has a convex arc-shaped end face at its end face, and fits the end face of an adjacent core piece block at the other end side. It has a concave arcuate end face that can be fitted, has a magnetic pole tooth 82b, and has a hole 82c. This first core piece block 8
When a plurality of two are continuously arranged, a first core member is formed.

The first core piece block 82 is obtained by inverting the one end side edge and the other end side of the first core piece block 82. The second core piece block 83 shown in FIG. 49B is connected to the other end side edge. A hole 83a serving as a part of the means, having a convex arc-shaped end face on one end face, and a concave arc-shaped end face fittable with an end face of an adjacent core piece block on one end side; It has a tooth 83b and a hole 83c. This second core piece block 8
The second core member is formed by continuously arranging a plurality of the three.

FIG. 50 shows the first core piece block 82 and the second core piece block 82.
The core piece blocks 83 are alternately stacked one tooth at a time. In this case, three first core piece blocks 82 and two second core piece blocks 83 are stacked. The first
Three core piece blocks 82 may be continuously stacked and two second core piece blocks 83 may be continuously stacked. Reference numeral 84 denotes one stacked tooth. The pin member 85 is connected to the hole 82c,
The entirety of the stacked teeth 84 is held and connected through a shaft 83c. The pin member 85 may be composed of a bolt and a nut.

When the first core piece block 82 and the second core piece block 83 for three teeth are stacked and arranged, for example, as shown in FIG. 51, the first core piece block 82 and the second core piece block 83 are arranged in a stacked manner. What is necessary is just to laminate | stack and arrange by the method which is easy to assemble. After that, the shaft connection is made by a pin member 85 for each tooth. Reference numerals 82 and 83 in FIG. 51 indicate a first core piece block and a second core piece block, respectively.

In the initial state shown in FIG. 52, holes 82a (part of the connecting means) at one end side edge of each first core piece block 82 and the other end side edge of each second core piece block 83 are provided. The hole 83a (part of the connecting means) is in communication with the hole in the stacking direction. Each of the first core piece blocks 82 and each of the second core piece blocks 83 are rotatably connected to each of the teeth 82a and 83a through a pin member 86 (a part of the connecting means) in teeth units. Thereby, the three teeth block 87 having the three teeth 84 stacked is temporarily fixed to three teeth.

Next, the insulating piece assembling step of FIG. 53 will be described. In the three-tooth block 87 in which the first and second core piece blocks 82 and 83 are stacked and arranged, reference numeral 88 denotes an insulating piece that covers both sides of each tooth 84, and 89 denotes an insulating cap that covers both ends of each tooth. To protect the wires, the teeth are covered with insulation. In the drawings showing the subsequent steps, the insulating piece 88 and the insulating cap 89 are not shown.

FIG. 54 shows the winding process. The three-tooth block 87 is rotated by the connecting means (holes 82a, 83a and the pin member 86) in units of the teeth 84 to make the teeth 84 in a reverse warp state. Teeth 84 at the tip,
Expand between 84. Winding is applied to each tooth 84 in a reverse warped state. 90 is a winding supply nozzle of the winding machine. In addition,
In the drawings showing the subsequent steps, the winding is not shown.

FIG. 55 shows a step of fixing the teeth 84 into three teeth blocks. The three teeth blocks 87 are rotated in units of teeth 84 by connecting means to be in a correct warp state, and the ends of the wound teeth 84 are applied. Teeth 84,8
Narrow between four. Then, the three-tooth block 87 forming a part of the annular core device is fixed.

FIG. 56 shows the entire circumference connecting step, in which three tooth blocks 87 which are wound and fixed are arranged so as to form a part of an annular shape, and are combined with each other to form the first
The hole 82a of the core piece block 82 and the hole 83a of each of the second core piece blocks 83 are in communication with each other in the stacking direction. Pin members 86 are inserted into these holes 82a and 83a.
To connect the three tooth blocks 87 together. The next three teeth block 87 is further connected to this connection in the same manner. This is repeated to obtain a complete annular core structure.

FIG. 57 shows the connection, varnishing, and shrink-fitting steps. In a complete annular iron core structure, the windings are connected between a plurality of 3-teeth blocks 87 having windings. Next, varnish treatment and shrink fitting are performed. Thus, the annular core device 91 for the electric motor is completed.

As described above, the first core piece block 82 in which a plurality of plate-shaped first core pieces are stacked and the second core piece block 83 in which a plurality of plate-shaped second core pieces are stacked are arranged and stacked. A first core member, in which a plurality of first core piece blocks 82 are continuously arranged, and a second core member, in which a plurality of second core piece blocks 83 are continuously arranged, are alternately arranged in the stacking direction.
The position between the first core piece blocks 82 of the first core member and the second
The core members are stacked such that the positions between the second core piece blocks 83 are shifted in the longitudinal direction, and the edges adjacent to each other in the stacking direction of the core piece blocks overlap. The edges of adjacent core piece blocks are connected by connecting means 82a, 83a, 86. Then, each core piece block is formed in an annular or rectangular shape by rotating each core piece block in teeth units by the connecting means, and the iron core device is completed.

In a medium-sized electric motor as in the thirteenth embodiment,
When the first core member is formed of a single piece of the core piece as in the third embodiment, the number of components becomes too large and the manufacturing becomes complicated. Therefore, in the thirteenth embodiment, a plurality of core pieces are stacked to form a core piece block, the number of components can be reduced, and productivity can be improved. Also, the core piece block is
It is smaller than the entire motor, has a simple shape, and can be used as a second core piece block if the first core piece block is turned over, so that the press die is small, simple, and inexpensive. Further, when three core blocks are formed by laminating a plurality of core pieces to form a core piece block, a connecting means is provided in comparison with an iron core device in which one core member is alternately laminated as shown in FIG. When rotating in teeth units, the friction is small and the rotation is easy.

[0096]

As described above, according to the present invention, it is possible to obtain a manufacturing method capable of manufacturing an iron core device with less deterioration of the connecting means and excellent magnetic performance with good workability.

[Brief description of the drawings]

FIG. 1 is a plan view showing a configuration of an iron core device of an electric motor according to Embodiment 1 of the present invention.

FIG. 2 is a plan view showing a step of forming the core member shown in FIG. 1 by press punching.

FIG. 3 is a cross-sectional view showing a configuration of a connecting portion of a core member formed through the process shown in FIG.

FIG. 4 is a plan view showing a state in which core members formed through the process shown in FIG. 2 are stacked.

FIG. 5 is a cross-sectional view illustrating a configuration of an edge of each core piece of the core member stacked as illustrated in FIG. 2;

FIG. 6 is a cross-sectional view showing a configuration different from FIG. 5 at an edge of each core piece of the laminated core member.

FIG. 7 is a plan view showing a configuration of a main part of the core device according to Embodiment 1 of the present invention, which is different from FIG. 1;

8 is a plan view showing a configuration of a main part of the iron core device in FIG. 7 in a state different from that in FIG. 7;

FIG. 9 is a plan view showing a configuration of a main part of the iron core device according to Embodiment 1 of the present invention, which is further different from FIG. 1;

10 is a plan view showing a configuration of a main part of the iron core device in FIG. 9 in a state different from that in FIG. 9;

FIG. 11 is a plan view showing a step of forming a core member of the core device by press punching in Embodiment 2 of the present invention.

FIG. 12 is a plan view showing a configuration of a first core member obtained in the step shown in FIG.

FIG. 13 is a plan view showing a configuration of a second core member obtained in the step shown in FIG.

FIG. 14 is a plan view showing a state where first and second core members in FIGS. 12 and 13 are stacked.

FIG. 15 is a perspective view showing a state where the first and second core members in FIGS. 12 and 13 are stacked.

FIG. 16 is a plan view showing a part of the configuration of an iron core device according to a second embodiment of the present invention.

FIG. 17 is an exploded perspective view showing a configuration of a main part of an iron core device according to Embodiment 3 of the present invention.

FIG. 18 is a plan view showing a configuration of a main part of an iron core device according to Embodiment 3 of the present invention, which is different from FIG. 17;

19 is a plan view showing a state different from that in FIG. 18 of a main part of the iron core device shown in FIG. 18;

FIG. 20 shows a configuration of a main part of an iron core device according to Embodiment 4 of the present invention, in which (A) is a cross-sectional view showing a state in which edges of core pieces at ends of a laminated core face each other; (B)
FIG. 4 is a cross-sectional view showing a state where the ends of the laminated core are in contact with each other.

FIG. 21 shows a configuration of a main part of an iron core device according to a fourth embodiment of the present invention, which is different from FIG. 20. FIG. 21 (A) shows a state in which edges of core pieces at ends of a laminated core face each other. (B) is a cross-sectional view showing a state in which the ends of the laminated core are in contact with each other.

FIG. 22 is a plan view showing a method of assembling the main parts of the iron core device according to Embodiment 5 of the present invention.

23 is a cross-sectional view showing a method of assembling the main parts of the iron core device shown in FIG. 22.

FIG. 24 is a front view showing a configuration of an iron core device according to Embodiment 6 of the present invention.

25 is a plan view showing material removal for forming the core member shown in FIG. 24 by press punching.

FIG. 26 is a plan view of a laminated core before assembling an iron core according to Embodiment 7 of the present invention.

FIG. 27 is a plan view showing an iron core device assembled using the laminated core of FIG. 26.

FIG. 28 is a plan view showing a configuration of an iron core device according to Embodiment 8 of the present invention.

FIG. 29 is a plan view showing a configuration of a core member shown in FIG. 28.

FIG. 30 is a plan view showing a main part of a core member of an iron core device according to Embodiment 8 of the present invention having a configuration different from that of FIG. 29.

31 is a plan view showing a configuration of a main part in a state where the core member shown in FIG. 30 is formed in an annular shape.

FIG. 32 is a plan view showing a main part of the core member having a configuration further different from that of FIG. 29.

FIG. 33 is a plan view showing a configuration of a main part in a state where the core member shown in FIG. 32 is formed in an annular shape.

FIG. 34 is a plan view showing a main part of the core member having a configuration further different from that of FIG. 32;

35 is a plan view showing a configuration of a main part in a state where the core member shown in FIG. 34 is formed in an annular shape.

FIG. 36 is an exploded perspective view showing a configuration of an iron core device according to Embodiment 9 of the present invention.

FIG. 37 is a plan view showing a configuration of a core member of an iron core device according to Embodiment 9 of the present invention which is different from that in FIG. 36.

FIG. 38 is a plan view showing an iron core device formed by forming the core member in FIG. 37 into an annular shape.

FIG. 39 is a plan view of a laminated core before assembling an iron core according to Embodiment 10 of the present invention.

40 is a plan view showing an iron core device assembled using the laminated core of FIG. 39.

FIG. 41 is a front view showing a configuration of a core device of a zero-phase current transformer according to Embodiment 11 of the present invention.

42 is a plan view showing a step of an assembling method of the core member of the iron core device in FIG. 41. FIG.

FIG. 43 is an operation diagram showing a step of rotating and bending the connecting means of the core member.

FIG. 44 is a diagram illustrating the principle of the present invention.

FIG. 45 is a front view showing a configuration of a motor core device according to a twelfth embodiment of the present invention.

46 is a plan view showing a step of an assembling method of the core member of the iron core device in FIG. 45.

FIG. 47 is a plan view showing a configuration of a main part of a core member in FIG. 46.

FIG. 48 is a plan view showing a main part of a core piece having a different connection portion between core pieces adjacent to each other in the arrangement direction.

FIG. 49 is a perspective view of a core piece block illustrating a core pressing step according to Embodiment 13 of the present invention.

FIG. 50 is a perspective view in which core piece blocks showing a shaft connecting step are stacked in a line.

FIG. 51 is an exploded perspective view of three teeth showing a stacking arrangement process.

FIG. 52 is an exploded perspective view of the three teeth, showing a step of temporarily fixing the three teeth.

FIG. 53 is an exploded perspective view of three teeth showing an insulating piece assembling step.

FIG. 54 is a perspective view of three teeth showing a winding step.

FIG. 55 is a perspective view showing a fixing step of forming three teeth blocks.

FIG. 56 is an exploded view of the iron core device showing the entire circumference connecting step.

FIG. 57 is a perspective view of the iron core device showing the steps of connection, varnishing, and shrink fitting.

FIG. 58 is a plan view showing a configuration of a conventional iron core device of a motor.

FIG. 59 is a plan view showing the configuration of the core member shown in FIG. 58.

[Explanation of symbols]

3, 8, 14, 18a, 19a, 22, 23, 40, 7
1,73,81 Core pieces, 3a, 8a, 51a, 52
b, 54a, 55b, 71a, 73a recess, 3b, 8
b, 23a, 51b, 52c, 54a, 55c, 71
b, 73b convex part, 3c, 3d, 14b, 14c, 71
c, 71d, 73c, 73d end face, 3e hole, 4,
9, 15, 20, 24, 53, 72 first core member,
5, 10, 16, 21, 25, 56, 74 Second core member, 6, 41 winding, 7, 11, 18, 19, 26, 5
8,78,91,98,115 Iron core device, 12,13
Notch, 17, 85, 86 pin member, 22a, 8
1a, 83a holes, 27, 28, 29, 30, 31, 3
2, 33, 34, 35, 36 abutment surfaces, 33a, 34
a, 35a, 36a engaging projections, 37, 38, 39 insulating bobbins, 51 first core piece A, 52 first core piece B, 54 second core piece A, 55 second core piece B, 57,
77, 93, 94, 95, 111, 112 laminated core,
82 1st core piece block, 83 2nd core piece block, 84 teeth, 87 3 teeth blocks

Continuation of the front page (72) Inventor Kenichi Higashi 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Inside Mitsubishi Electric Corporation (72) Inventor Takashi Anamura 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsubishi Electric Corporation (56) References JP-A-10-155248 (JP, A) JP-A-9-308143 (JP, A) JP-A-7-222383 (JP, A) JP-A-8-275468 (JP, A) JP-A-3-78447 (JP, A) JP-A-9-191588 (JP, A) JP-A-10-285880 (JP, A) JP-A-7-7875 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) H02K 15/02 H02K 1/18

Claims (6)

(57) [Claims] A first core member in which a plurality of independent plate-shaped first core pieces are continuously arranged; and a second core member in which a plurality of independent plate-shaped second core pieces are continuously arranged. However, the positions between the first core pieces of the first core member and the positions between the second core pieces of the second core member are shifted in the longitudinal direction alternately in the laminating direction, so that the laminating direction of the core pieces is A step of laminating so that adjacent edges overlap each other, a connecting means comprising a concave portion and a convex portion provided at an edge of each core piece, and a connecting means provided on the first core piece and the second means. A method of manufacturing an iron core device comprising a step of alternately stacking connecting means provided on a core piece to form a rotation axis in a stacking direction and rotatably connecting edges of adjacent core pieces to each other. . 2. The method for manufacturing an iron core device according to claim 1, wherein the step of laminating the core pieces and the step of connecting the core pieces are performed simultaneously by crimping. 3. A step of expanding each of the stacked core members by rotating each of the core pieces by a connecting means; a step of applying a winding to each of the expanded core members; 2. The method for manufacturing an iron core device according to claim 1, further comprising a step of forming each of the core members on which the windings are formed into an annular or rectangular shape by rotating a core piece. 4. The method for manufacturing an iron core device according to claim 3, wherein the step of deploying each core member includes a step of regulating the deployment. 5. The method for manufacturing an iron core according to claim 3, wherein the step of forming each core member in an annular or rectangular shape includes a step of restricting rotation of each core piece. 6. A first arrangement in which a plurality of first core piece blocks in which a plurality of independent plate-shaped first core pieces are stacked are continuously arranged.
A core member and a second core member in which a plurality of second core piece blocks in which a plurality of independent plate-shaped second core pieces are stacked are continuously arranged in the stacking direction alternately in the stacking direction. The position between each first core piece block and each second core member
A step of stacking so that the positions between the core piece blocks are displaced in the longitudinal direction, and edges adjacent to each other in the stacking direction of the core piece blocks overlap with each other; The connecting means provided on the first core piece block and the connecting means provided on the second core piece block are alternately stacked to form a rotation axis in the stacking direction. A method for manufacturing an iron core device, comprising: a step of rotatably connecting edges of respective core piece blocks.