Method for manufacturing laminated rotor core

• US 8,234,775 B2
• Filed: 02/27/2008
• Issued: 08/07/2012
• Est. Priority Date: 02/28/2007
• Status: Expired due to Fees

• Current Assignee: Aisin Seiki Co., Ltd. (Aisin Corp.)
• Original Assignee: Aisin Seiki Co., Ltd. (Aisin Corp.)
• Inventors: Hoshino, Akinori, Suzuki, Haruji, Kamio, Shusaku
• Primary Examiner(s): ARBES, CARL J
• Application Number:
  US12/037,988
• Publication Number:
  US 20080201936A1
• Time in Patent Office: 1,623 Days
• Field of Search: 295/96, 295/98, 296/05, 296/09, 310/216
• US Class Current: 29/598
• CPC Class Codes: H02K 15/03 having permanent magnets
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49078 Laminated

Abstract

A method for manufacturing a laminated rotor core includes a punching process for punching a strip-shaped material to make a core piece, a placing process, which is performed simultaneously with the punching process of the core piece, for placing the core piece in a die so that the core piece is placed on another core piece previously punched and placed in the die and a joining process for joining the core pieces.

Claims

1. A method for manufacturing an annular-shaped laminated rotor core, the method comprising:

punching a strip-shaped material to produce a punched-out arc-shaped core piece which is punched-out from the strip-shaped material;

placing the punched-out arc-shaped core piece in a die;

rotating the die relative to the strip-shaped material; and

repeating the punching of the strip-shaped material, the placing of the punched-out arc-shaped core piece in the die, and the rotating of the die relative to the strip-shaped material to position subsequent punched-out arc-shaped core pieces in the die adjacent each other in a circumferential direction and in a laminating direction, and so that the core pieces are coiled into a spiral shape.

2. The method for manufacturing the annular-shaped laminated rotor core according to claim 1, wherein the punched-out arc-shaped core pieces which are adjacent in the laminating direction are joined together in the die.

3. The method for manufacturing the annular-shaped laminated rotor core according to claim 2, wherein the joining together comprises fitting an embossed portion on a surface of one of the punched-out arc-shaped core pieces into an embossed portion on a surface of the punched-out arc-shaped core piece which is adjacent the one punched-out arc-shaped core piece in the laminating direction, and so that the core pieces are coiled into a spiral shape.

4. The method for manufacturing the annular-shaped laminated rotor core according to claim 1, wherein the punching comprises punching two or more strips of the strip-shaped material are punched simultaneously by a punch to simultaneously produce two of the punched-out arc-shaped core pieces.

5. The method for manufacturing the annular-shaped laminated rotor core according to claim 1, wherein the strip-shaped material is a grain-oriented electrical steel sheet and the grain-oriented electrical steel sheet is punched so that an easy magnetization direction of the grain-oriented electrical steel sheet corresponds to a predetermined direction.

6. The method for manufacturing the annular-shaped laminated rotor core according to claim 1, wherein the die is rotated to circumferentially offset the punched-out arc-shaped core pieces relative to the punched-out arc-shaped core pieces which are adjacent in the laminating direction.

7. The method for manufacturing the annular-shaped laminated rotor core according to claim 1, wherein the punching of the strip-shaped material and the placing of the punched-out arc-shaped core piece in the die are performed using a punch and the die which has a ring-shaped die hole.

8. The method for manufacturing the annular-shaped laminated rotor core according to claim 1, wherein each arc-shaped core piece includes a magnet installation through hole configured to accommodate a magnet, a sleeve installation through hole configured to install a sleeve, and an embossed portion, the method further comprising fitting the embossed portion on a surface of one of the punched-out arc-shaped core pieces into the embossed portion on a surface of the punched-out arc-shaped core piece which is adjacent the one punched-out arc- shaped core piece in the laminating direction.

9. A method for manufacturing an annular-shaped laminated rotor core, the method comprising:

positioning a strip-shaped material adjacent a die;

punching the strip-shaped material a plurality of times to produce a plurality of first punched-out arc-shaped core pieces and pushing each of the first punched-out arc-shaped core pieces into the die to position the first punched-out arc-shaped core pieces adjacent one another in a circumferentially direction; and

further punching the strip-shaped material a plurality of times to produce a plurality of second punched-out arc-shaped core pieces and pushing each of the second punched-out arc-shaped core pieces into the die to position the second punched-out arc-shaped core pieces adjacent one another in the circumferentially direction and to position the second punched-out arc-shaped core pieces adjacent the first punched-out arc-shaped core pieces in a laminating direction so that the first and second punched-out arc-shaped core pieces are coiled into a spiral shape.

10. The method for manufacturing the annular-shaped laminated rotor core according to claim 9, wherein the second punched-out arc-shaped core pieces which are adjacent the first punched-out arc-shaped core pieces in the laminating direction are joined together in the die.

11. The method for manufacturing the annular-shaped laminated rotor core according to claim 10, wherein the joining together comprises fitting an embossed portion on a surface of one of each of the first punched-out arc-shaped core pieces into an embossed portion on a surface of one of the second punched-out arc-shaped core pieces.

12. The method for manufacturing the annular-shaped laminated rotor core according to claim 9, wherein the positioning of the strip-shaped material adjacent the die comprises positioning at least two strip-shaped materials adjacent the die, and wherein the punching of the strip-shaped material a plurality of times to produce the first punched-out arc-shaped core pieces comprises simultaneously punching the at least two strips of the strip-shaped material.

13. The method for manufacturing the annular-shaped laminated rotor core according to claim 9, wherein the strip-shaped material is a grain-oriented electrical steel sheet and the grain-oriented electrical steel sheet is punched so that an easy magnetization direction of the grain-oriented electrical steel sheet corresponds to a predetermined direction.

14. The method for manufacturing the annular-shaped laminated rotor core according to claim 9, wherein the strip-shaped material is punched by a punch, and wherein the die is rotated after each punch of the strip-shaped material.

15. The method for manufacturing the annular-shaped laminated rotor core according to claim 9, wherein the strip-shaped material is punched by a punch, and wherein the die is rotated after each punch of the strip-shaped material to circumferentially offset the second punched-out arc-shaped core pieces relative to the first punched-out arc-shaped core pieces.

16. The method for manufacturing the annular-shaped laminated rotor core according to claim 9, wherein each of the first and second punched-out arc-shaped core pieced includes a magnet installation through hole configured to accommodate a magnet, a sleeve installation through hole configured to install a sleeve, and an embossed portion, the method further comprising fitting the embossed portion on a surface of one of the second punched-out arc-shaped core pieces into the embossed portion on a surface of the first punched-out arc-shaped core piece which is adjacent the second punched-out arc-shaped core piece in the laminating direction.