Method of manufacturing stacked core and apparatus for manufacturing stacked core

Patent metadata

Field	Value
Publication number	US-11469652-B2
Application number	US-201916519011-A
Country	US
Kind code	B2
Filing date	Jul 23, 2019
Priority date	Jan 25, 2017
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

A method of manufacturing a stacked core includes forming a first pilot hole in a metal plate, forming a worked portion of the metal plate in a state in which a first pilot pin is inserted into the first pilot hole, the worked portion being displaced relative to a plane of the metal plate, press-fitting the worked portion of the metal plate to reposition the worked portion to extend along the plane of the metal plate, forming a second pilot hole in the metal plate after press-fitting the worked portion of the metal plate, and forming a blanked member by blanking the metal plate in a state in which a second pilot pin is inserted into the second pilot hole, the blanked member including the worked portion.

First claim

The invention claimed is:

1. A method of manufacturing a stacked core, the method comprising:
forming a first pilot hole in a metal plate by a first punch;
inserting a first pilot pin into the first pilot hole in order to align the metal plate with a second punch;
forming a worked portion of the metal plate by the second punch, after inserting the first pilot pin into the first pilot hole, wherein the worked portion is moved downwardly away from a plane of the metal plate while the first pilot pin is at least partially located in the first pilot hole;
press-fitting the worked portion of the metal plate by pressing the worked portion upwardly toward the plane of the metal plate, thereby generating a displacement of the first pilot hole along the plane of the metal plate after the first pilot pin is inserted into the first pilot hole;
forming a second pilot hole in the metal plate by a third punch, after press-fitting the worked portion of the metal plate;
inserting a second pilot pin into the second pilot hole in order to align the metal plate with a fourth punch; and
forming a blanked member by blanking the metal plate by the fourth punch, after inserting the second pilot pin into the second pilot hole, wherein the blanked member includes the worked portion, and wherein the blanked member is formed while the second pilot pin is at least partially located in the second pilot hole.

2. The method according to claim 1 , wherein the second pilot hole formed by the third punch is located at a position in the metal plate that coincides with the first pilot hole, wherein a diameter of the second pilot hole is larger than a diameter of the first pilot hole.

3. The method according to claim 1 , further comprising:
forming a slot-corresponding hole in the metal plate by blanking a second region of the metal plate by a fifth punch, the second region corresponding to a slot of a stacked stator core, after forming the first pilot hole and before forming the worked portion by the second punch;
inserting a third pilot pin into the second pilot hole, before the second pilot pin is inserted into the second pilot hole;
forming a center-corresponding hole in the metal plate by blanking a third region in the metal plate by a sixth punch, the third region corresponding to a center hole positioned at a center of the stacked stator core and in which a rotor is disposed, while the third pilot pin is at least partially located in the second pilot hole, after forming the second pilot hole and before forming the blanked member; and
removing the third pilot pin from the second pilot hole.

4. The method according to claim 3 , further comprising:
forming a through hole in the metal plate by a seventh punch, before forming the worked portion by the second punch;
blanking a blanked rotor member for a stacked rotor core from the metal plate by an eighth punch through a die held by a rotatable die holder, after forming the through hole and before forming the worked portion by the second punch, wherein the rotatable die holder is adapted to rotate the blanked rotor member relative to the metal plate;
inserting a fourth pilot pin into the through hole; and
stacking the blanked rotor member on another blanked rotor member previously blanked from the metal plate, while the fourth pilot pin is at least partially located in the through hole and is at least partially located in an engagement hole in the rotatable die holder to restrain the rotatable die holder from rotating relative to the metal plate.

5. The method according to claim 1 , wherein the blanked member is formed in each of multiple lines shifted in pitch in a width direction of the metal plate.

6. An apparatus for manufacturing the stacked core according to the method of claim 1 , the apparatus comprising:
a feeder configured to feed the metal plate;
the first to fourth punches;
the first and second pilot pins;
a driver comprising a driving mechanism configured to drive the first to fourth punches and the first and second pilot pins based on instruction signals from a controller; and
the controller communicably connected to the feeder and the driver, wherein the controller is configured to:
control the feeder to sequentially feed the metal plate,
control the driver to form the first pilot hole in the metal plate by the first punch,
control the driver to insert the first pilot pin into the first pilot hole,
control the driver to form the worked portion of the metal plate by the second punch, while the first pilot pin is at least partially located in the first pilot hole,
control the driver to form the second pilot hole in the metal plate by the third punch, after the worked portion of the metal plate is press-fitted into the metal plate,
control the driver to insert the second pilot pin into the second pilot hole, and
control the driver to form the blanked member by blanking the metal plate by the fourth punch, while the second pilot pin is at least partially located in the second pilot hole.

7. The apparatus according to claim 6 , wherein the second pilot hole is formed by the third punch at a position in the metal plate that coincides with the first pilot hole, wherein the second pilot hole has a diameter that is greater than a diameter of the first pilot hole, and wherein the third punch is located downstream the first pilot pin in a feeding direction of the feeder.

8. The apparatus according to claim 6 , further comprising:
a third pilot pin; and
fifth and sixth punches,
wherein the controller is further configured to:
control the driver to form a slot-corresponding hole in the metal plate by blanking a second region in the metal plate that corresponds to a slot of a stacked stator core by the fifth punch, after forming the first pilot hole and before forming the worked portion by the second punch,
control the driver to insert the third pilot pin into the second pilot hole, before the second pilot pin is inserted into the second pilot hole,
control the driver to form a center-corresponding hole in the metal plate by blanking a third region in the metal plate by the sixth punch, the third region corresponding to a center hole positioned at a center of the stacked stator core and in which a rotor is disposed, while the third pilot pin is at least partially located in the second pilot hole, after forming the second pilot hole and before forming the blanked member; and
control the driver to remove the third pilot pin from the second pilot hole.

9. The apparatus according to claim 8 , further comprising
seventh and eighth punches;
a fourth pilot pin; and
a rotatable die holder having an engagement hole configured to be engaged with the fourth pilot pin,
wherein the controller is further configured to:
control the driver to form a through hole in the metal plate by the seventh punch before working the predetermined portion by the second punch,
control the driver to insert the fourth pilot pin into the through hole, and
control the driver to blank a blanked rotor member for a stacked rotor core from the metal plate by the eighth punch through a die held by the rotatable die holder so that the blanked rotor member is stacked on another blanked rotor member already blanked from the metal plate, while the fourth pilot pin is at least partially located in the through hole and is at least partially located in the engagement hole to restrain the rotatable die holder from rotating, after forming the through hole and before forming the worked portion by the second punch.

10. The apparatus according to claim 6 , wherein the blanked member is formed in each of multiple lines shifted in pitch in a width direction of the metal plate.

Assignees

• Mitsui High Tec

Inventors

• Hashimoto Akihiro
• Komiya Daisuke

Classifications

• H02K1/26

  Rotor cores with slots for windings · CPC title

• H02K1/22

  Rotating parts of the magnetic circuit · CPC title

• B21D28/24

  Perforating, i.e. punching holes · CPC title

• H02K1/16

  Stator cores with slots for windings · CPC title

• B21D39/00

  Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating ({joining mitred profiles B21D53/745; } riveting B21J; uniting components by forging or pressing to form integral members B21K25/00; welding B23K; press-fitting, force-fitting, or shrinking in general B23P11/00, B21D19/00; by adhesives F16B11/00 {; Connections as such F16L, F16B}); Tube expanders · CPC title