Device for manufacturing laminated iron core and method for manufacturing laminated iron core

This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2019-160461 filed on Sep. 3, 2019, the contents of which are incorporated herein by reference.

The present disclosure relates to a device for manufacturing a laminated iron core and a method for manufacturing a laminated iron core.

JP2018-007530A discloses a method for manufacturing a rotor laminated iron core in which a strip-shaped metal sheet is sent intermittently, an inner diameter region is punched from each metal sheet, a plurality of shaft holes provided with key protruding portions is formed such that the protruding portions face different angles; an outer diameter region including each shaft hole is separately punched from the metal sheet to form a plurality of punched members; and a plurality of the punched members are laminated while being rotated such that the protruding portions overlap with each other.

According to the method described in JP2018-007530A, in order to form the plurality of shaft holes such that the protruding portions each face different angles, a plurality of punches for forming the shaft holes are arranged in a line in a longitudinal direction of the metal sheet. Therefore, if the punches are not accurately aligned, the protruding portions may be displaced in a height direction of the rotor laminated iron core when the plurality of punched members are laminated.

According to the method described in JP2018-007530A, the shaft hole is formed by one punch, so that the punch includes a first portion corresponding to the protruding portion, and a second portion corresponding to an opening portion of the shaft hole. Since the protruding portion has a relatively complicated shape such as an uneven shape, the first portion tends to be damaged relatively easily. When the first portion is damaged, the entire punch including the second portion needs to be replaced, which may increase the maintenance cost.

The present disclosure describes a device for manufacturing a laminated iron core and a method for manufacturing a laminated iron core with which a laminated iron core can be manufactured with high accuracy and low cost.

According to an illustrative aspect of the present disclosure, a device for manufacturing a laminated iron core by punching out a plurality of punched members from a metal sheet and laminating the plurality of punched members while being rotated, the plurality of punched members having an annular shape and having M number of protrusions provided on an inner peripheral edge or an outer peripheral edge of the plurality of punched members, the M being a natural number of 1 or more, includes: a punch unit configured to form the protrusions, and including N number of punches as a set, the N being the natural number larger than the M; and N number of auxiliary punches. The N number of auxiliary punches are configured such that L number of auxiliary punches selected from the N number of auxiliary punches performs a nullification processing on the metal sheet, the nullification processing being configured to nullify a processing with the L number of punches among the N number of punches, the L being the natural number that is obtained by subtracting the M from the N.

According to another illustrative aspect of the present disclosure, a method for manufacturing a laminated iron core by punching out a plurality of punched members from a metal sheet and laminating the plurality of punched members while being rotated, the plurality of punched members having an annular shape and having M number of protrusions provided on an inner peripheral edge or an outer peripheral edge of the plurality of punched members, the M being a natural number of 1 or more, includes: processing the metal sheet with a punch unit of forming the protrusions, and including N number of punches as a set, the N being a natural number larger than the M; and performing a nullification processing on the metal sheet with L number of auxiliary punches selected from the N number of auxiliary punches so as to nullify a processing with the L number of punches among the N number of punches, the L being the natural number that is obtained by subtracting the M from the N.

According to the device for manufacturing a laminated iron core and the method for manufacturing a laminated iron core of the present disclosure, a laminated iron core can be manufactured with high accuracy and low cost.

FIG. 1 is an exploded perspective view showing an example of a rotor.

FIG. 2 is a schematic view showing an example of a device for manufacturing a laminated iron core.

FIG. 3 is a schematic sectional view showing an example of a press processing device.

FIG. 4 is a top view schematically showing an example of a punch included in the press processing device.

FIG. 5 is a diagram showing an example of a layout for punching a rotor laminated iron core.

FIG. 6 is a diagram showing an example of a layout for punching the rotor laminated iron core.

FIG. 7 is a diagram showing an example of a layout for punching the rotor laminated iron core.

FIG. 8 is a top view schematically showing another example of a punch included in the press processing device.

FIG. 9 is a perspective view showing an example of a stator laminated iron core.

FIG. 10 is a top view schematically showing still another example of a punch included in the press processing device.

FIG. 11 is a diagram showing an example of a layout for punching a stator laminated iron core.

FIG. 12 is a diagram showing an example of a layout for punching the stator laminated iron core.

FIG. 13 is a perspective view showing an example of an intermediate body that configures the stator laminated iron core.

Hereinafter, an example of an embodiment according to the present disclosure will be described in more detail with reference to the drawings. In the following description, the same elements or elements having the same functions will be denoted by the same reference numerals, and repetitive descriptions thereof will be omitted.

[Configuration of Rotor]

First, the configuration of a rotor 1 (rotor) will be described with reference to FIG. 1 . The rotor 1 is combined with a stator (stator) to form an electric motor (motor). The rotor 1 may form a part of an embedded magnet type (IPM) motor, or may form a part of another type of motor, for example. The rotor 1 includes a rotor laminated iron core 2 (laminated iron core) and a shaft 3 .

The rotor laminated iron core 2 includes a laminated body 10 (laminated iron core), a plurality of permanent magnets 12 , and a plurality of solidified resins 14 .

The laminated body 10 has a cylindrical shape. An shaft hole 10 a penetrating the laminated body 10 is provided in a central portion of the laminated body 10 . The shaft hole 10 a extends along a center axis Ax. The shaft hole 10 a extends in a height direction (upper-lower direction) of the laminated body 10 . Since the laminated body 10 rotates around the center axis Ax, the center axis Ax is also a rotation axis.

At least one protruding ridge 10 b is provided on an inner peripheral surface of the shaft hole 10 a . The protruding ridge 10 b extends in the height direction from an upper end surface 51 to a lower end surface S 2 of the laminated body 10 . The protruding ridge 10 b protrudes from the inner peripheral surface of the shaft hole 10 a toward the center axis Ax. The number of the protruding ridges 10 b may be two. In this case, the two protruding ridges 10 b may be arranged so as to face each other with the center axis Ax therebetween.

A plurality of magnet-insert holes 16 are formed in the laminated body 10 . The magnet-insert holes 16 are arranged at predetermined intervals along an outer peripheral edge of the laminated body 10 . The magnet-insert holes 16 penetrate the laminated body 10 in a manner of extending along the center axis Ax. That is, the magnet-insert holes 16 extend in the height direction.

The laminated body 10 is configured by laminating a plurality of punched members W. The punched members W are plate-shaped body formed by punching a metal sheet MS (for example, electromagnetic steel plate) described below into predetermined shapes, so as to form a shape corresponding to the laminated body 10 . That is, the punched members W have an annular shape as a whole, and include a center hole Wa corresponding to the shaft hole 10 a , a protrusion Wb corresponding to the protruding ridge 10 b , and a through hole We corresponding to the magnet-insert hole 16 . That is, at least one protrusion Wb is provided on an inner peripheral edge of the punched members W.

The laminated body 10 may be configured by so-called rotating lamination. The term “rotating lamination” refers to laminating a plurality of punched members W while relatively shifting angles of the punched members W. The rotating lamination is performed mainly for the purpose of offsetting the plate thickness deviation of the punched members W and increasing the flatness, parallelism, and perpendicularity of the laminated body 10 . The angles of the rotating lamination may be set to any size.

The punched members W adjacent to each other in the laminating direction may be interlocked by a caulk portion 18 . The punched members W may also be interlocked to each other by various known methods instead of the caulk portion 18 . For example, the plurality of punched members W may be joined together through using an adhesive or a resin material, or may be joined together by welding.

One permanent magnet 12 is inserted into each magnet-insert hole 16 . A shape of the permanent magnet 12 is not particularly limited, and the permanent magnet 12 may have a rectangular parallelepiped shape. A type of the permanent magnet 12 may be determined according to the use, the required performance, and the like of the motor, and may be, for example, a sintered magnet or a bonded magnet.

The solidified resin 14 is obtained by solidifying a resin material in a molten state (molten resin) filled in the magnet-insert hole 16 in which the permanent magnet 12 is housed. The solidified resin 14 may be configured to fix the permanent magnet 12 in the magnet-insert hole 16 . The solidified resin 14 may be configured to bond the punched members W adjacent to each other in the upper-lower direction.

The shaft 3 has a cylindrical shape as a whole. The shaft 3 is formed with a pair of concave grooves 3 a . The concave groove 3 a extends along the longitudinal direction of the shaft 3 from one end to the other end of the shaft 3 . The shaft 3 is inserted into the shaft hole 10 a . In a state where the shaft 3 is inserted into the shaft hole 10 a , the protruding ridges 10 b engage with the concave grooves 3 a . Accordingly, the shaft 3 is fixed to the rotor laminated iron core 2 , and a rotational force is transmitted between the shaft 3 and the rotor laminated iron core 2 .

[Configuration of Device for Manufacturing Laminated Iron Core]

Next, a manufacturing device 100 of a laminated iron core will be described with reference to FIG. 2 . The manufacturing device 100 is configured to manufacture the laminated body 10 from the strip-shaped metal sheet MS. As shown in FIG. 2 , the manufacturing device 100 includes an uncoiler 110 , a feeding device 120 , a press processing device 130 , and a controller Ctr (control unit).

The uncoiler 110 is configured to rotatably hold a coil material 111 . The coil material 111 is a metal sheet MS wound in a coil shape (spiral shape). The feeding device 120 includes a pair of rollers 121 , 122 sandwiching the metal sheet MS from an upper side and a lower side. The pair of rollers 121 , 122 rotate and stop based on an instruction signal from the controller Ctr, and intermittently and sequentially feed the metal sheet MS to the press processing device 130 .

The press processing device 130 is configured to operate based on an instruction signal from the controller Ctr. The press processing device 130 may be configured to sequentially punch the metal sheet MS fed by the feeding device 120 with a plurality of punches, so as to form a plurality of punched members W, for example. The press processing device 130 may be configured to sequentially laminate the plurality of punched members W obtained by punching, so as to form the laminated body 10 . The configuration of the press processing device 130 will be described later.

The controller Ctr is configured to generate an instruction signal for operating the feeding device 120 and the press processing device 130 based on a program recorded in a recording medium (not shown) or an operation input from an operator, for example. The controller Ctr is configured to send the instruction signal to the feeding device 120 and the press processing device 130 , separately.

[Details of Press Processing Device]

Next, the details of the press processing device 130 will be described with reference to FIGS. 3 and 4 . As shown in FIG. 3 , the press processing device 130 includes a lower die 140 , an upper die 150 , and a pressing machine 160 . The lower die 140 includes a base 141 , a die holder 142 , die members D 1 to D 6 , a plurality of guide posts 143 , and a transport mechanism 144 .

The base 141 is fixed on a floor surface, for example, and functions as a base of the entire press processing device 130 . The die holder 142 is supported on the base 141 . The die holder 142 is formed with a plurality of discharge holes C 1 to C 6 . The die holder 142 may be made of, for example, a steel material (raw material) that has not been subjected to heat treatment such as quenching.

The plurality of discharge holes C 1 to C 6 may extend inside the die holder 142 in the upper-lower direction (see arrow Z in FIG. 3 ). The material punched out from the metal sheet MS (for example, the punched member W, waste material or the like) is discharged to the plurality of discharge holes C 1 to C 6 .

The die members D 1 to D 6 are attached to an upper portion of the die holder 142 so as to be adjacent to each other in a transport direction of the metal sheet MS. The plurality of die members D 1 to D 6 are arranged in this order from the upstream side to the downstream side in the transport direction of the metal sheet MS.

The die member D 1 includes a die plate D 11 and a die D 12 . The die plate D 11 is configured to hold the die D 12 in a through hole provided in a central portion. The die plate D 11 may be made of, for example, a steel material that has been subjected to heat treatment such as quenching. The die D 12 may be made of, for example, a cemented carbide containing tungsten carbide.

As shown in FIGS. 3 and 4 , the die D 12 is formed with a die hole D 13 penetrating in the upper-lower direction. The die hole D 13 configures a unit for punching the metal sheet MS together with a punch P 1 described later. The through hole We corresponding to the magnet-insert hole 16 may be formed in the metal sheet MS by punching the metal sheet MS with the unit.

The die hole D 13 may have a shape corresponding to the magnet-insert hole 16 , or may have a rectangular shape or the like. The number of die holes D 13 may be the same as the number of magnet-insert holes 16 formed in the laminated body 10 . As illustrated in FIG. 4 , the plurality of die holes D 13 may be arranged at substantially equal intervals so as to form a circular shape as a whole.

Returning to FIG. 3 , the die holes D 13 communicate with the discharge hole C 1 . By inserting and removing the punch P 1 in and from the die hole D 13 , the metal sheet MS is punched in a shape along a contour of the die hole D 13 . A metal piece punched out from the metal sheet MS is discharged to the outside of the press processing device 130 through the discharge hole C 1 .

The die member D 2 includes a die plate D 21 and a die D 22 . The die plate D 21 is configured to hold the die D 22 in a through hole provided in a central portion. The material of the die plate D 21 may be the same as the material of the die plate D 11 , and the material of the die D 22 may be the same as the material of the die D 12 .

As shown in FIGS. 3 and 4 , the die D 22 is formed with a die hole D 23 penetrating in the upper-lower direction. The die hole D 23 configures a unit for half punching or punching the metal sheet MS together with a punch P 2 described later. In the case of half punching, the punch P 2 may press the metal sheet MS into the die hole D 23 to an extent that the metal sheet MS is not punched, so as to form an unevenness corresponding to the caulk portion 18 on the metal sheet MS. In the case of punching, the punch P 2 may punch the metal sheet MS, so as to form a through hole corresponding to the caulk portion 18 in the metal sheet MS.

The die hole D 23 may have a shape corresponding to the caulk portion 18 , or may have a circular shape, a rectangular shape, or the like. The number of die holes D 23 may be the same as the number of caulk portion 18 formed in the laminated body 10 . As illustrated in FIG. 4 , the plurality of die holes D 23 may be arranged at substantially equal intervals so as to form a circular shape as a whole.

Returning to FIG. 3 , the die holes D 23 communicate with the discharge hole C 2 . By inserting and removing the punch P 2 in the die hole D 23 , the metal sheet MS is half punched or punched in a shape along a contour of the die hole D 23 . A metal piece punched out from the metal sheet MS is discharged to the outside of the press processing device 130 through the discharge hole C 2 .

The die member D 3 includes a die plate D 31 and a die D 32 . The die plate D 31 is configured to hold the die D 32 in a through hole provided in a central portion. The material of the die plate D 31 may be the same as the material of the die plate D 11 , and the material of the die D 32 may be the same as the material of the die D 12 .

As shown in FIGS. 3 and 4 , the die D 32 is formed with a die hole D 33 penetrating in the upper-lower direction. The die hole D 33 configures a unit for punching the metal sheet MS together with a punch P 3 described later. A part of the center hole Wa may be formed in the metal sheet MS by punching the metal sheet MS with the unit.

The die hole D 33 may be located inside a region where the center hole Wa of the punched member W is to be formed in the metal sheet MS. The die hole D 33 may have, for example, an annular sector shape. The number of die holes D 33 may be set according to an angle of the rotating lamination. For example, when the angle of the rotating lamination is 180°, the number of die holes D 33 may be two; when the angle of the rotating lamination is 120°, the number of die holes D 33 may be three; when the angle of the rotating lamination is 90°, the number of die holes D 33 may be four; when the angle of the rotating lamination is 60°, the number of die holes D 33 may be six; and when the angle of the rotating lamination is 45°, the number of die holes D 33 may be eight. As illustrated in FIG. 4 , the plurality of die holes D 23 may be arranged at substantially equal intervals so as to form a circular shape as a whole.

Returning to FIG. 3 , the die holes D 33 communicate with the discharge hole C 3 . By inserting and removing the punch P 3 in the die hole D 33 , the metal sheet MS is punched in a shape along a contour of the die hole D 33 . A metal piece punched out from the metal sheet MS is discharged to the outside of the press processing device 130 through the discharge hole C 3 .

The die member D 4 includes a die plate D 41 and a die D 42 . The die plate D 41 is configured to hold the die D 42 in a through hole provided in a central portion. The material of the die plate D 41 may be the same as the material of the die plate D 11 , and the material of the die D 42 may be the same as the material of the die D 12 .

As shown in FIGS. 3 and 4 , the die D 42 is formed with a die hole D 43 penetrating in the upper-lower direction. The die hole D 43 configures a unit for punching the metal sheet MS together with a punch P 4 described later. The protrusion Wb may be formed in the metal sheet MS by punching the metal sheet MS with the unit.

The die hole D 43 may be located inside a region where the center hole Wa of the punched member W is to be formed in the metal sheet MS. The die hole D 43 may have, for example, an annular sector shape as a whole. The die hole D 43 may be provided with a protruding ridge D 43 a protruding from an outer side to an inner side on the outer peripheral edge. The number of the die holes D 43 may be the same as that of the die holes D 33 . As illustrated in FIG. 4 , the plurality of die holes D 23 may be arranged at substantially equal intervals so as to form a circular shape as a whole. As illustrated in FIG. 4 , the die member D 4 may include a plurality of dies D 42 , and one die hole D 43 may be formed in each of the plurality of dies D 42 respectively. In this case, the plurality of dies D 42 may be held in the through hole of the die plate D 41 so as to be arranged in a circular shape as a whole.

Returning to FIG. 3 , the die holes D 43 communicate with the discharge hole C 4 . By inserting and removing the punch P 4 in the die hole D 43 , the metal sheet MS is punched in a shape along a contour of the die hole D 43 . A metal piece punched out from the metal sheet MS is discharged to the outside of the press processing device 130 through the discharge hole C 4 .

The die member D 5 includes a die plate D 51 and a die D 52 . The die plate D 51 is configured to hold the die D 52 in a through hole provided in a central portion. The material of the die plate D 51 may be the same as the material of the die plate D 11 , and the material of the die D 52 may be the same as the material of the die D 12 .

As shown in FIGS. 3 and 4 , the die D 52 is formed with a die hole D 53 penetrating in the upper-lower direction. The die hole D 53 configures a unit for punching the metal sheet MS together with a punch P 5 described later. The remaining part of the center hole Wa may be formed in the metal sheet MS by punching the metal sheet MS with the unit.

The die hole D 53 may have, for example, a circular shape as a whole. The die hole D 53 may be provided with a protruding ridge D 53 a protruding from a peripheral edge toward the center on the peripheral edge. The number of the protruding ridges D 53 a may be the same as that of the die holes D 33 , D 43 . As illustrated in FIG. 4 , the plurality of protruding ridges D 53 a may be arranged at substantially equal intervals in a circumferential direction of the die hole D 53 .

Returning to FIG. 3 , the die holes D 53 communicate with the discharge hole C 5 . By inserting and removing the punch P 5 in the die hole D 53 , the metal sheet MS is punched in a shape along a contour of the die hole D 53 . A metal piece punched out from the metal sheet MS is discharged to the outside of the press processing device 130 through the discharge hole C 5 .

The die member D 6 includes a die plate D 61 , a die D 62 , and a drive mechanism D 64 . The die plate D 61 is configured to hold the die D 62 in a through hole provided in a central portion. The die D 62 may be held with respect to the die plate D 61 so as to be rotatable about a center axis extending along a vertical direction. A die holder may be interposed between the die plate D 61 and the die D 62 , and the die holder may be rotatably held with respect to the die plate D 61 . The material of the die plate D 61 may be the same as the material of the die plate D 11 , and the material of the die D 62 may be the same as the material of the die D 12 .

As shown in FIGS. 3 and 4 , the die D 62 is formed with a die hole D 63 penetrating in the upper-lower direction. The die hole D 63 configures a unit for punching the metal sheet MS together with a punch P 6 described later. The punched member W may be formed in the metal sheet MS by punching the metal sheet MS with the unit. The die hole D 63 may have, for example, a circular shape as a whole.

Returning to FIG. 3 , the die holes D 63 communicate with the discharge hole C 6 . By inserting and removing the punch P 6 in the die hole D 63 , the metal sheet MS is punched in a shape along a contour of the die hole D 63 . The punched member W punched out from the metal sheet MS is laminated on a punched member W punched out previously, while being interlocked to each other by the caulk portion 18 in the die hole D 63 . When a predetermined number of punched members W are laminated in the die hole D 63 , the obtained laminated body 10 is placed on the transport mechanism 144 through the discharge hole C 6 .

The drive mechanism D 64 is connected to the die D 62 . The drive mechanism D 64 rotates the die D 62 around the center axis of the die D 62 based on the instruction signal from the controller Ctr. Therefore, after the punched member W punched out from the metal sheet MS is laminated on the punched member W punched out previously, the die D 62 is rotated by a predetermined angle, so that the succeeding punched member W is laminated on and rotated with respect to the preceding punched member W. The drive mechanism D 64 may be implemented by, for example, a combination of a rotary motor, gears, a timing belt, or the like.

As shown in FIG. 3 , the plurality of guide posts 143 linearly extend upward from the die holder 142 . The plurality of guide posts 143 , together with guide bushes 151 a (to be described later), are configured to guide the upper die 150 in the upper-lower direction. The plurality of guide posts 143 may be attached to the upper die 150 so as to extend downward from the upper die 150 .

The transport mechanism 144 is configured to operate based on an instruction from the controller Ctr and send the laminated body 10 dropped from the die D 62 to a subsequent device (for example, a magnet attachment device, a resin injection device, a welding device, a shaft attachment device or the like). The transport mechanism 144 is disposed such that one end of the transport mechanism 144 is located inside the discharge hole C 6 , and the other end of the transport mechanism 144 is located outside the press processing device 130 . The transport mechanism 144 may be, for example, a belt conveyor.

The upper die 150 includes a punch holder 151 , a stripper 152 , a plurality of punches P 1 to P 6 , and a switching device 153 . The punch holder 151 is arranged above the die holder 142 so as to face the die holder 142 . The punch holder 151 is configured to hold the plurality of punches P 1 to P 6 on a lower surface side thereof.

The punch holder 151 is provided with a plurality of guide bushes 151 a . The plurality of guide bushes 151 a are located so as to correspond to the plurality of guide posts 143 , respectively. The guide bush 151 a has a cylindrical shape, and the guide post 143 can be inserted into an internal space of the guide bush 151 a . When the guide post 143 is attached to the upper die 150 , the guide bush 151 a may be provided on the lower die 140 .

The punch holder 151 is provided with a plurality of through holes 151 b . A step-like step is formed on an inner peripheral surface of the through hole 151 b . Therefore, a diameter of an upper portion of the through hole 151 b is set smaller than a diameter of a lower portion of the through hole 151 b.

The stripper 152 is configured to remove from the punches P 1 to P 6 the metal sheet MS that is punched into the punches P 1 to P 6 when the metal sheet MS is punched with the punches P 1 to P 6 . The stripper 152 is arranged between the die members D 1 to D 6 and the punch holder 151 .

The stripper 152 is connected to the punch holder 151 via a connecting member 152 a . The connecting member 152 a includes an elongated main body portion and a head portion provided on an upper end of the main body portion. The main body portion of the connecting member 152 a is inserted into the lower portion of the through hole 151 b and can move up and down in the through hole 151 b . A lower end of the main body portion of the connecting member 152 a is fixed to the stripper 152 . A biasing member 152 b such as a compression coil spring may be attached around the main body portion of the connecting member 152 a so as to be located between the punch holder 151 and the stripper 152 .

The head portion of the connecting member 152 a is arranged on the upper portion of the through hole 151 b . An outer shape of the head portion of the connecting member 152 a is set to be larger than an outer shape of the main body portion of the connecting member 152 a when viewed from above. Therefore, the head portion of the connecting member 152 a can move up and down in the upper portion of the through hole 151 b , but the step of the through hole 151 b functions as a stopper and cannot move to the lower portion of the through hole 151 b . Therefore, the stripper 152 is suspended and held by the punch holder 151 so as to be movable up and down relative to the punch holder 151 .

The stripper 152 is provided with through holes at positions corresponding to punches P 1 to P 6 , respectively. Each through hole extends in the upper-lower direction. Each of the through holes communicates with the corresponding die holes D 13 to D 63 when viewed from above. Lower portions of the punches P 1 to P 6 are inserted into the respective through holes. The lower portions of the punches P 1 to P 6 are slidable in the respective through holes.

The punches P 1 to P 6 are arranged in this order from the upstream side to the downstream side of the press processing device 130 . A lower end portion of the punch P 1 has a shape corresponding to the die hole D 13 . The lower end portion may be, for example, a columnar body having a rectangular cross section. The number of the punches P 1 may be the same as that of the die holes D 13 . As illustrated in FIG. 4 , the plurality of punches P 1 may be arranged at substantially equal intervals so as to form a circular shape as a whole.

When the press processing device 130 includes a plurality of punches P 1 , the plurality of punches P 1 may form a set of punch unit for forming the through holes We corresponding to the magnet-insert holes 16 . That is, the plurality of punches P 1 may be configured to punch the metal sheet MS at substantially the same time in the same punching process.

A lower end portion of the punch P 2 has a shape corresponding to the die hole D 23 . The lower end portion may be, for example, a columnar body having a circular cross section or a rectangular cross section. The number of the punches P 2 may be the same as that of the die holes D 23 . As illustrated in FIG. 4 , the plurality of punches P 2 may be arranged at substantially equal intervals so as to form a circular shape as a whole.

When the press processing device 130 includes a plurality of punches P 2 , the plurality of punches P 2 may form a set of punch unit for forming the through holes or the unevenness corresponding to the caulk portions 18 . That is, the plurality of punches P 2 may be configured to half punch or punch the metal sheet MS at substantially the same time in the same punching process. The switching between the half-punching and the punching by the plurality of punches P 2 may be performed by a device similar to the switching device 153 .

A lower end portion of the punch P 3 (auxiliary punch) has a shape corresponding to the die hole D 33 . The lower end portion may be, for example, a columnar body having an annular sector-shaped cross section. The number of the punches P 3 may be the same as that of the die holes D 33 . As illustrated in FIG. 4 , the plurality of punches P 3 may be arranged at substantially equal intervals so as to form a circular shape as a whole. A biasing member 154 such as a compression coil spring may be attached around a lower end portion of the punch P 3 so as to be located between the head portion of the punch P 3 and the stripper 152 .

When the press processing device 130 includes a plurality of punches P 3 , the plurality of punches P 3 may form a set of punch unit (auxiliary punch unit) for forming the part of the center hole Wa. That is, the plurality of punches P 3 may be configured to punch the metal sheet MS at substantially the same time in the same punching process.

A lower end portion of the punch P 4 has a shape corresponding to the die hole D 43 . The lower end portion may be, for example, a columnar body having an annular sector-shaped cross section. At least an outer peripheral surface of the lower end portion of the punch P 4 may be provided with, for example, a concave groove P 4 a extending in the upper-lower direction. The number of the punches P 4 may be the same as that of the die holes D 43 . As illustrated in FIG. 4 , the plurality of punches P 4 may be arranged at substantially equal intervals so as to form a circular shape as a whole.

When the press processing device 130 includes a plurality of punches P 4 , the plurality of punches P 4 may form a set of punch unit (punch unit for forming protrusion) for forming the protrusions Wb. That is, the plurality of punches P 4 may be configured to punch the metal sheet MS at substantially the same time in the same punching process.

A lower end portion of the punch P 5 has a shape corresponding to the die hole D 53 . The lower end portion may be, for example, a columnar body having a circular cross section as a whole. At least an outer peripheral surface of the lower end portion of the punch P 5 may be provided with, for example, a concave groove P 5 a extending in the upper-lower direction. The number of the concave grooves P 5 a may be the same as that of the die holes D 33 , D 43 . As illustrated in FIG. 4 , the plurality of concave groove P 5 a may be arranged at substantially equal intervals in a peripheral direction of the punch P 5 .

A lower end portion of the punch P 6 has a shape corresponding to the die hole D 63 . The lower end portion may be, for example, a columnar body having a circular cross section.

As illustrated in FIG. 3 , the switching device 153 may be arranged above the punch P 3 and inside the punch holder 151 . When the press processing device 130 includes a plurality of punches P 3 , the same number of switching devices 153 as the plurality of punches P 3 may be arranged above the punches P 3 so as to correspond to the respective punches P 3 .

The switching device 153 is, for example, a cam mechanism, and includes a cam member 153 a and an actuator 153 b . The cam member 153 a is configured to be slidable in a horizontal direction. On a lower surface side of the cam member 153 a , a concave portion 153 c recessed upward is provided. The concave portion 153 c is configured such that the head portion of the punch P 3 can be housed therein.

The actuator 153 b is configured to drive the cam member 153 a in the horizontal direction based on an instruction signal from the controller Ctr. The actuator 153 b may be configured to move the cam member 153 a between a first position where the head portion of the punch P 3 is located outside the concave portion 153 c and is in contact with a lower surface of the cam member 153 a and a second position where the head portion of the punch P 3 is housed in the concave portion 153 c , for example. The actuator 153 b may be arranged outside the upper die 150 instead of inside the punch holder 151 .

The pressing machine 160 is located above the upper die 150 . A piston of the pressing machine 160 is connected to the punch holder 151 and operates based on an instruction signal from the controller Ctr. When the pressing machine 160 operates, the piston thereof expands and contracts, and the upper die 150 moves up and down as a whole.

When the cam member 153 a is in the first position (see FIG. 3 ), a tip end portion of the punch P 3 is located relatively downward. In a case where the punch P 3 is in such a protruding state, when the pressing machine 160 operates and the upper die 150 moves downward, the tip end portion of the punch P 3 is inserted into the die hole D 33 , so that the metal sheet MS is punched.

On the other hand, when the cam member 153 a is in the second position, the punch P 3 moves relatively upward due to a biasing force of the biasing member 154 , and the head portion of the punch P 3 is housed in the concave portion 153 c . In a case where the punch P 3 is in such a retracted state, when the pressing machine 160 operates and the upper die 150 moves downward, the tip end portion of the punch P 3 is not inserted into the die hole D 33 and does not contact the metal sheet MS, so that the metal sheet MS is not processed at all. In this way, the switching device 153 is configured to be able to selectively change the state of the punch P 3 .

[Method for Manufacturing Laminated Body]

Next, a method for manufacturing the laminated body 10 will be described with reference to FIGS. 4 to 7 . Hereinafter, a description will be given based on an example of the manufacturing device 100 including six punches P 3 , six punches P 4 , six punches P 5 provided with the concave groove P 5 a , and six switching devices 153 , in which states of the six punches P 3 can be individually controlled by the corresponding switching devices 153 (see FIG. 4 ).

When the metal sheet MS is intermittently fed to the press processing device 130 by the feeding device 120 and a predetermined part of the metal sheet MS reaches the die member D 1 , the pressing machine 160 operates to push the upper die 150 downward toward the lower die 140 . Even after the stripper 152 reaches the metal sheet MS and the metal sheet MS is sandwiched between the stripper 152 and the die member D 1 , the pressing machine 160 pushes the upper die 150 downward.

At this time, the stripper 152 does not move, but the punch holder 151 and the punches P 1 to P 6 continue to move downward. Therefore, the tip end portions of the punches P 1 to P 6 move downward in the respective through holes of the stripper 152 and further reach the die holes D 13 to D 63 . In this process, the punch P 1 punches the metal sheet MS along the die hole D 13 . As a result, the through hole We corresponding to the magnet-insert hole 16 is formed in the metal sheet MS. The waste material punched out is discharged from the discharge hole C 1 . Then, the pressing machine 160 operates to raise the upper die 150 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS reaches the die member D 2 , the upper die 150 is moved up and down by the pressing machine 160 , and the half punching or punching of the metal sheet MS by the punch P 2 is performed similarly to the above. As a result, the unevenness or through holes corresponding to the caulk portion 18 is formed in the metal sheet MS. The waste material punched out is discharged from the discharge hole C 2 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS (refer to a processing area A 1 in FIG. 5 ) reaches the die member D 3 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching (nullification processing) of the metal sheet MS by the punch P 3 is performed similarly to the above. When the controller Ctr controls each switching device 153 such that the two punches P 3 located in the phases of 0° and 180° are in the retracted state and the remaining four punches P 3 are in the protruding state, four through holes R 1 are formed in the metal sheet MS at positions corresponding to the four punches P 3 (refer to the black-painted areas in the processing area A 1 in FIG. 5 ). The through hole R 1 has a shape corresponding to the punch P 3 and the die hole D 33 . In the example of FIG. 5 , the through hole R 1 may have an annular sector shape. The waste material punched out is discharged from the discharge hole C 3 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS (refer to a processing area A 2 in FIG. 5 ) reaches the die member D 4 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching (protrusion forming processing) of the metal sheet MS by the punch P 4 is performed similarly to the above. Since the four through holes R 1 are formed in the previous process, the four punches P 4 located in the phases of 60°, 120°, 240° and 300° pass through the corresponding through holes R 1 without coming into contact with the metal sheet MS. On the other hand, the two punches P 4 located at the phases of 0° and 180° punch the metal sheet MS. As a result, two through holes R 2 are formed in the metal sheet MS at positions corresponding to the two punches P 4 (refer to the black-painted areas in the processing area A 2 in FIG. 5 ). The through hole R 2 has a shape corresponding to the punch P 4 and the die hole D 43 . In the example of FIG. 5 , the through hole R 2 has an annular sector shape as a whole, and the protrusion Wb protruding from the outer peripheral edge toward the inner peripheral edge may be provided on the outer peripheral edge. The waste material punched out is discharged from the discharge hole C 4 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS (refer to a processing area A 3 in FIG. 5 ) reaches the die member D 5 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching of the metal sheet MS by the punch P 5 is performed similarly to the above. At this time, since an outer peripheral surface of the punch P 5 is provided with the concave grooves P 5 a in the phases of 0°, 60°, 120°, 180°, 240°, and 300°, respectively, the concave grooves P 5 a located in the phase of 0° and 180° pass through the corresponding protrusions Wb. That is, the punch P 5 punches the metal sheet MS without punching the protrusions Wb (inner-shape blanking processing). Since the through holes R 1 and R 2 are formed in the metal sheet MS in the previous process, the black-painted area in the processing area A 3 of FIG. 5 is punched out from the metal sheet MS by the punch P 5 . As a result, the center hole Wa is formed in the metal sheet MS. The waste material punched out is discharged from the discharge hole C 5 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS reaches the die member D 6 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching of the metal sheet MS by the punch P 6 (outer-shape blanking processing) is performed similarly to the above. As a result, the punched member W in which the protrusions Wb are located at the phases of 0° and 180° is formed. The punched member W after being punched is laminated on a punched member W punched previously in the die hole D 63 .

In the processing area A 1 , when the controller Ctr controls each switching device 153 such that the two punches P 3 located in the phases of 60° and 240° are in the retracted state and the remaining four punches P 3 are in the protruding state, four through holes R 1 are formed in the metal sheet MS at positions corresponding to the four punches P 3 (refer to the black-painted areas in the processing area A 1 in FIG. 6 ). In this case, in the subsequent process, the four punches P 4 located in the phases of 0°, 120°, 180°, and 300° pass through the corresponding through holes R 1 without coming into contact with the metal sheet MS. On the other hand, the two punches P 4 located at the phases of 60° and 240° punch the metal sheet MS. As a result, two through holes R 2 are formed in the metal sheet MS at positions corresponding to the two punches P 4 (refer to the black-painted areas in the processing area A 2 in FIG. 6 ).

Further, in the subsequent process, when the punch P 5 moves up and down, the concave grooves P 5 a located at the phases of 60° and 240° pass through the corresponding protrusions Wb. That is, the punch P 5 punches the metal sheet MS without punching the protrusions Wb (inner-shape blanking processing). Since the through holes R 1 and R 2 are formed in the metal sheet MS in the previous process, the black-painted area in the processing area A 3 of FIG. 6 is punched out from the metal sheet MS by the punch P 5 . As a result, the center hole Wa is formed in the metal sheet MS. Further, in the subsequent process, the punching of the metal sheet MS (outer-shape blanking processing) is performed by the punch P 6 , so as to form the punched member W in which the protrusions Wb are located at the phases of 60° and 240°.

In the processing area A 1 , when the controller Ctr controls each switching device 153 such that the two punches P 3 located in the phases of 120° and 300° are in the retracted state and the remaining four punches P 3 are in the protruding state, four through holes R 1 are formed in the metal sheet MS at positions corresponding to the four punches P 3 (refer to the black-painted areas in the processing area A 1 in FIG. 7 ). In this case, in the subsequent process, the four punches P 4 located in the phases of 0°, 60°, 180°, and 240° pass through the corresponding through holes R 1 without coming into contact with the metal sheet MS. On the other hand, the two punches P 4 located at the phases of 120° and 300° punch the metal sheet MS. As a result, two through holes R 2 are formed in the metal sheet MS at positions corresponding to the two punches P 4 (refer to the black-painted areas in the processing area A 2 in FIG. 7 ).

Further, in the subsequent process, when the punch P 5 moves up and down, the concave grooves P 5 a located at the phases of 120° and 300° pass through the corresponding protrusions Wb. That is, the punch P 5 punches the metal sheet MS without punching the protrusions Wb (inner-shape blanking processing). Since the through holes R 1 and R 2 are formed in the metal sheet MS in the previous process, the black-painted area in the processing area A 3 of FIG. 7 is punched out from the metal sheet MS by the punch P 5 . As a result, the center hole Wa is formed in the metal sheet MS. Further, in the subsequent process, the punching of the metal sheet MS (outer-shape blanking processing) is performed by the punch P 6 , so as to form the punched member W in which the protrusions Wb are located at the phases of 120° and 300°.

The punched members W punched out as described above are laminated while being rotated in the die hole D 63 such that the protrusions Wb overlap with each other in the height direction. Thereafter, when a predetermined number of punched members W are laminated, the laminated body 10 is completed.

[Effects]

According to the above embodiment, the metal sheet MS is processed by the unit including the plurality of punches P 4 as a set to form the protrusions Wb. That is, a processing position by the plurality of punches P 4 is limited to one position (processing area A 2 ) in the longitudinal direction of the metal sheet MS. Therefore, the positional accuracy of the protrusions Wb formed by the plurality of punches P 4 is improved, and thus when the plurality of punched members W are laminated, the displacement of the protrusions Wb in the height direction of the laminated body 10 is less likely to occur. Further, according to the above example, the unit of the punches P 4 for forming the protrusions Wb and the punches P 5 for the inner-shape blanking are separate bodies. Therefore, even if one of the punches P 4 of the unit is damaged, it is not necessary to replace the punch P 5 for the inner-shape blanking, and the maintainability of the manufacturing device 100 is improved. As a result, the laminated body 10 can be manufactured with high accuracy and low cost.

According to the above embodiment, the position of the punch P 3 in the retracted state can be switched to a different position at a predetermined timing. In this case, by laminating these punched members W while being rotated, it is possible to offset the plate thickness deviation of the punched members W and increase the flatness, parallelism, and perpendicularity of the laminated body 10 . The predetermined timing may be a regular timing (for example, every time the nullification processing described above is performed) or an irregular timing.

According to the above embodiment, the unit including the plurality of punches P 4 as a set can be arranged at the downstream side from the punch P 3 . In this case, first, the nullification processing by the punch P 3 is performed on the metal sheet MS, and then the protrusions Wb are formed by the punches P 4 on the metal sheet MS. Therefore, the punches P 4 do not contact the metal sheet MS at the location where the nullification processing is already performed (through holes R 1 ). Therefore, as compared with the case where a plurality of protrusions Wb are formed by the plurality of punches P 4 and then a predetermined number of protrusions Wb are subjected to the nullification processing (punching) by the punch P 3 , scraps are less likely to occur and burrs are less likely to be formed on the metal sheet MS. As a result, the laminated body 10 can be formed with higher quality.

According to the above embodiment, the plurality of punches P 3 may be a set of units and configured to be individually operable by the corresponding switching device 153 . In this case, the processing position by the plurality of punches P 3 is limited to one position (processing area A 1 ) in the longitudinal direction of the metal sheet MS. That is, it is not necessary to arrange the plurality of punches P 3 side by side along the longitudinal direction of the metal sheet MS. Therefore, the number of processes for the nullification processing is reduced. Therefore, a production time of the laminated body 10 can be shortened, and the productivity can be improved.

According to the above embodiment, the press processing device 130 may include a plurality of dies D 42 respectively corresponding to the plurality of punches P 4 . In this case, the dies D 42 are also individualized, so that even if a predetermined die D 42 is damaged when forming the protrusion Wb, only the damaged die D 42 needs to be replaced. Therefore, the maintainability of the manufacturing device 100 is further improved, and the laminated body 10 can be manufactured at a lower cost.

[Modifications]

It should be understood that the disclosure in the present description is merely illustrated in all respect and not restrictive. Various omissions, substitutions, and changes may be made to the above examples without departing from the scope of the claims and the gist thereof.

(1) The manufacturing device 100 may include a plurality of die members D 3 . The plurality of die members D 3 may be arranged in a line along the transport direction of the metal sheet MS. The die D 32 of each die member D 3 may be provided with at least one die hole D 33 . For example, the plurality of punches P 3 for nullification processing may not be grouped as a unit. In other words, the plurality of punches P 3 for nullification processing may include one punch P 3 arranged in the relatively upstream side in the transport direction of the metal sheet MS, and the other punch P 3 arranged at the downstream side of the one punch P 3 . In this case, the other punch P 3 is configured to perform the nullification processing on the metal sheet MS at a timing (at a different processing position) different from that of the one punch P 3 .

In the example shown in FIG. 8 , the manufacturing device 100 includes three die members D 3 . The die D 32 of the die member D 3 located upstream includes die holes D 33 located at phases of 0° and 180°, respectively. The die D 32 of the die member D 3 located in the middle includes die holes D 33 located at phases of 60° and 240°, respectively. The die D 32 of the die member D 3 located at downstream includes die holes D 33 located at phases of 120° and 300°, respectively. In this case, among an upstream side processing unit configured by an upstream die member D 3 and a punch P 3 corresponding thereto, a middle processing unit configured by a middle die member D 3 and a punch P 3 corresponding thereto, and a downstream side processing unit configured by a downstream die member D 3 and a punch P 3 corresponding thereto, any two of the processing units perform the nullification processing on the metal sheet MS, while the remaining one processing unit does not perform the nullification processing, and the metal sheet MS is transported to the die member D 4 . At this time, the punches P 3 corresponding to the two processing units are in the protruding state, and the punch P 3 corresponding to the remaining processing unit is in the retracted state.

(2) A unit including a plurality of punches P 4 as a set may be arranged on the upstream side of the punches P 3 . Alternatively, the punches P 3 and P 4 may be arranged such that a part of the plurality of punches P 3 , the unit including the plurality of punches P 4 as a set, and the rest of the plurality of punches P 3 are arrange in order from the upstream side.

(3) When manufacturing a laminated iron core other than the rotor laminated iron core 2 , the manufacturing device 100 described above may be used. As shown in FIG. 9 , the other laminated iron core may be a stator laminated iron core 20 in which a plurality of annular punched members W are laminated. The stator laminated iron core 20 has a cylindrical shape. That is, a through hole 20 a which extends along a center axis Ax is provided in a central portion of the stator laminated iron core 20 . The rotor 1 may be arranged in the through hole 20 a.

The stator laminated iron core 20 includes one yoke portion 22 , a plurality of tooth portions 24 , and at least one lug portion 26 . The yoke portion 22 has an annular shape and extends so as to surround the center axis Ax. Each of the plurality of tooth portions 24 extends from an inner peripheral edge of the yoke portion 22 toward the center axis Ax side along a radial direction of the yoke portion 22 . The plurality of tooth portions 24 may be arranged at substantially equal intervals in a peripheral direction of the yoke portion 22 .

A winding wire (not shown) may be wound around each tooth portion 24 . A slot 20 b , which is a space for arranging the winding wire, is defined between the adjacent tooth portions 24 . Each tooth portion 24 is provided with a caulk portion 28 . Like the caulk portion 18 , the caulk portion 28 is configured to bond the punched members W adjacent to each other in the laminating direction.

The lug portion 26 protrudes radially outward from an outer peripheral edge of the yoke portion 22 so as to be separated from the center axis Ax. The lug portion 26 extends linearly in the height direction from one end surface to the other end surface of the stator laminated iron core 20 . When the stator laminated iron core 20 includes a plurality of lug portions 26 , the plurality of lug portions 26 may be arranged at substantially equal intervals in the peripheral direction of the yoke portion 22 .

Each lug portion 26 is provided with a through hole 20 c extending in the height direction. Bolts for fixing the stator laminated iron core 20 to other members (for example, a housing of an electric motor) can be inserted into the through holes 20 c.

The punched members W have a shape corresponding to the stator laminated iron core 20 . That is, the punched members W have an annular shape as a whole, and include a center hole Wa corresponding to the through hole 20 a , a protrusion Wb corresponding to the lug portion 26 , a through hole We corresponding to the slot 20 b , and a through hole Wd corresponding to the through hole 20 c . That is, at least one protrusion Wb is provided on an outer peripheral edge of the punched members W.

When manufacturing such a stator laminated iron core 20 , the manufacturing device 100 may include die members D 1 to D 6 illustrated in FIG. 10 and punches P 1 to P 6 corresponding to the die members D 1 to D 6 , respectively. A die D 12 of the die member D 1 may be provided with a plurality of die holes D 13 having a shape corresponding to the slot 20 b . A die D 22 of the die member D 2 may be provided with a plurality of die holes D 23 having a shape corresponding to the caulk portion 28 . A die D 32 of the die member D 3 may be provided with a plurality of die holes D 33 having a shape corresponding to the through holes 20 a and 20 c . The lower end portions of the punches P 1 to P 3 may have shapes corresponding to the die holes D 13 , D 23 , D 33 , respectively.

A die D 42 of the die member D 4 may be provided with a die hole D 43 for nullification processing. The die hole D 43 may be located outside a region where the punched member W is to be formed in the metal sheet MS. The die hole D 43 may have, for example, an annular sector shape. A lower end portion of the punch P 4 may have a shape corresponding to the die hole D 43 .

A die D 52 of the die member D 5 may be provided with a die hole D 53 for forming the protrusion Wb. The die hole D 53 may be located outside a region where the punched member W is to be formed in the metal sheet MS. The die hole D 43 may have, for example, an annular sector shape as a whole. The die hole D 53 may be provided with a protruding ridge D 53 a protruding from an inner side to an outer side on the inner peripheral edge. A lower end portion of the punch P 5 may have a shape corresponding to the die hole D 53 . An inner peripheral surface of the lower end portion may be provided with, for example, a concave groove P 5 a extending in the upper-lower direction.

A die D 62 of the die member D 6 may be provided with a die hole D 63 for outer-shape blanking processing. The die hole D 63 may have, for example, a circular shape as a whole. The die hole D 53 may be provided with a concave groove D 63 a which is recessed outward from the peripheral edge on the peripheral edge. The number of the concave grooves D 63 a may be the same as that of the die holes D 43 , D 53 . A lower end portion of the punch P 6 may have a shape corresponding to the die hole D 63 . An outer peripheral surface of the lower end portion may be provided with, for example, a protruding ridge P 6 a extending in the upper-lower direction.

Next, a method for manufacturing the stator laminated iron core 20 will be described with reference to FIGS. 10 to 12 . Hereinafter, a description will be given based on an example of the manufacturing device 100 including six punches P 4 , six punches P 5 , six punches P 6 provided with the protruding ridges P 6 a , and six switching devices 153 , in which states of the six punches P 4 can be individually controlled by the corresponding switching devices 153 (see FIG. 10 ).

When the metal sheet MS is intermittently fed to the press processing device 130 by the feeding device 120 and a predetermined part of the metal sheet MS reaches the die member D 1 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching of the metal sheet MS by the punch P 1 is performed. As a result, the through hole We corresponding to the slot 20 b is formed in the metal sheet MS. The waste material punched out is discharged from the discharge hole C 1 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS reaches the die member D 2 , the upper die 150 is moved up and down by the pressing machine 160 , and the half punching or punching of the metal sheet MS by the punch P 2 is performed similarly to the above. As a result, the unevenness or through holes corresponding to the caulk portion 28 is formed in the metal sheet MS. The waste material punched out is discharged from the discharge hole C 2 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS (refer to a processing area B 1 in FIG. 11 ) reaches the die member D 3 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching of the metal sheet MS by the punch P 3 is performed similarly to the above. As a result, the through hole Wd corresponding to the through hole 20 c is formed in the metal sheet MS (refer to the black-painted areas in the processing area B 1 in FIG. 11 ). The waste material punched out is discharged from the discharge hole C 3 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS (refer to a processing area B 2 in FIG. 11 ) reaches the die member D 4 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching (nullification processing) of the metal sheet MS by the punch P 4 is performed similarly to the above. When the controller Ctr controls each switching device 153 such that the three punches P 4 located in the phases of 60°, 180°, and 300° are in the retracted state and the remaining three punches P 4 are in the protruding state, three through holes R 1 are formed in the metal sheet MS at positions corresponding to the latter three punches P 4 (refer to the black-painted areas in the processing area B 2 in FIG. 11 ). At this time, the through hole Wd formed at the position overlapping the through hole R 1 is removed from the metal sheet MS. The waste material punched out is discharged from the discharge hole C 4 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS (refer to a processing area B 5 in FIG. 11 ) reaches the die member D 5 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching (protrusion forming processing) of the metal sheet MS by the punch P 5 is performed similarly to the above. At this time, since the three through holes R 1 are formed in the previous process, the three punches P 5 located in the phases of 0°, 120°, and 240° pass through the corresponding through holes R 1 without coming into contact with the metal sheet MS. On the other hand, the three punches P 5 located at the phases of 60°, 180°, and 300° punch the metal sheet MS. As a result, three through holes R 2 are formed in the metal sheet MS at positions corresponding to the latter three punches P 5 (refer to the black-painted areas in the processing area B 3 in FIG. 11 ). The waste material punched out is discharged from the discharge hole C 5 .

Next, when the metal sheet MS is intermittently sent by the feeding device 120 and the predetermined part of the metal sheet MS (refer to a processing area B 4 in FIG. 11 ) reaches the die member D 6 , the upper die 150 is moved up and down by the pressing machine 160 , and the punching (outer-shape blanking processing) of the metal sheet MS by the punch P 6 is performed similarly to the above. At this time, since an outer peripheral surface of the punch P 6 is provided with the protruding ridges P 6 a in the phases of 0°, 60°, 120°, 180°, 240°, and 300°, respectively, the protruding ridges P 6 a located in the phase of 0°, 120°, and 240° pass through the corresponding through holes R 1 . On the other hand, the protruding ridges P 6 a located at the phases of 60°, 180°, and 300° punch the metal sheet MS so as to form the protrusions Wb. As a result, the punched member W in which the protrusions Wb are located at the phases of 60°, 180°, and 300° is formed.

In the processing area B 1 , when the controller Ctr controls each switching device 153 such that the three punches P 4 located in the phases of 0°, 120°, and 240° are in the retracted state and the remaining three punches P 4 are in the protruding state, three through holes R 1 are formed in the metal sheet MS at positions corresponding to the latter three punches P 4 (refer to the black-painted areas in the processing area B 2 in FIG. 12 ). In this case, in the subsequent process, the three punches P 5 located in the phases of 60°, 180°, and 300° pass through the corresponding through holes R 1 without coming into contact with the metal sheet MS. On the other hand, the three punches P 5 located at the phases of 0°, 120°, and 240° punch the metal sheet MS. As a result, three through holes R 2 are formed in the metal sheet MS at positions corresponding to the latter three punches P 5 (refer to the black-painted areas in the processing area B 3 in FIG. 12 ).

Further, in the subsequent process, when the punch P 6 moves up and down, the protruding ridges P 6 a located at the phases of 60°, 180°, and 300° pass through the corresponding through holes R 1 . On the other hand, the three punches P 6 located at the phases of 0°, 120°, and 240° punch the metal sheet MS. As a result, the punched member W in which the protrusions Wb are located at the phases of 0°, 120°, and 240° is formed.

The punched members W punched out as described above are laminated while being rotated in the die hole D 63 such that the protrusions Wb overlap with each other in the height direction. Thereafter, when a predetermined number of punched members W are laminated, the stator laminated iron core 20 is completed.

(4) When manufacturing an intermediate laminated body including a temporary caulking portion, the manufacturing device 100 described above may be used. Thereafter, the temporary caulking portion is removed from the intermediate laminated body, so that a laminated body to be the rotor laminated iron core may be formed, or a laminated body to be the stator laminated iron core may be formed. The temporary caulking portion may be provided on an inner peripheral surface of the intermediate laminated body, or may be provided on an outer peripheral surface of the intermediate laminated body. The term “temporary caulking portion” refers to a caulking portion which is used to temporarily integrate a plurality of punched members W and is removed in the process of manufacturing a laminated body.

An example of the intermediate laminated body 30 will be described with reference to FIG. 13 . The intermediate laminated body 30 includes a stator laminated iron core 20 and a temporary caulking portion 31 provided on an outer peripheral surface of the stator laminated iron core 20 . The intermediate laminated body 30 is configured by laminating a plurality of punched members W. The punched member W is in a state in which a temporary caulking piece 41 corresponding to the temporary caulking portion 31 is fitted to an outer peripheral edge of a process plate 50 corresponding to the stator laminated iron core 20 . The punched members W adjacent to each other in the height direction of the intermediate laminated body 30 are interlocked to each other via a caulk portion 42 provided on the temporary caulking piece 41 .

Cutting lines CL are provided between the temporary caulking piece 41 and the process plate 50 . Each cutting line CL may be formed, for example, by performing a cutting and bending processing or a punching processing on the metal sheet MS, and then pushing back the processed portion and press-fitting into the original metal sheet MS. When the metal sheet MS is subjected to the cutting and bending processing or the punching processing, the processed portion is plastically deformed and slightly extends. Therefore, when the processed portion is press-fitted into the original metal sheet MS, the processed portion and the original metal sheet MS are firmly fitted to each other to an extent of not being able to be easily separated by hand.

(5) The manufacturing device 100 may be used when forming a punched member W in which M (M being a natural number of 1 or more) protrusions Wb are provided on an inner peripheral edge or an outer peripheral edge. In this case, the manufacturing device 100 may include a punch unit including N (N being a natural number larger than M) punches P 4 as a set and N punches P 3 . The punch unit may include, for example, six punches P 4 or eight punches P 4 . In this case, the manufacturing device 100 may include the same number of punches P 3 and punches P 4 . Therefore, even if the number of punches P 4 included in the punch unit increases, the number of punches P 3 does not exceed the number of punches P 4 . Therefore, the configuration of the device is simplified, so that the manufacturing cost of the manufacturing device 100 can be reduced.