Method for manufacturing a stator core for an axial air-gap electronic motor

Abstract

There is provided a method for manufacturing a stator core for an axial air-gap electronic motor, in which core sheets are laminatedly fixed while being shifted with predetermined intervals. The method includes a step in which first side surfaces in the circumferential direction (first slot surfaces 25) of the first to nth (n is a positive integer) core sheets are blanked out of a mother sheet 60 by moving first blanking punches 360 with predetermined intervals via a first control means 700; and a second blanking step in which second side surfaces in the circumferential direction (second slot surfaces 26) of the first to nth (n is a positive integer) core sheets are blanked in succession by moving a second blanking punch 460 with predetermined intervals via a second control means 700.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view schematically showing an axial air-gap electronic motor manufactured by a manufacturing method in accordance with the present invention;

FIG. 2 is a front view of a stator of the axial air-gap electronic motor shown in FIG. 1;

FIG. 3A is a front view of a pole member constituting the stator shown in FIG. 2;

FIG. 3B is a perspective view of a pole member constituting the stator shown in FIG. 2;

FIG. 4 is a schematic view of a die section of a manufacturing apparatus for an axial air-gap electronic motor in accordance with one embodiment of the present invention;

FIG. 5 is a main longitudinal sectional view of a drive section of a manufacturing apparatus;

FIG. 6 is a transverse sectional view of a first blanking stage;

FIG. 7 is a transverse sectional view of a second blanking stage;

FIG. 8 is a front view showing a state of a mother sheet at each stage;

FIG. 9 is an explanatory view for explaining movement of a first blanking punch and a second blanking punch; and

FIG. 10 is a front view showing a state in which core sheets are disassembled and arranged in order from the inside diameter side to the outside diameter side.

Claims

1. A method for manufacturing a stator core for an axial air-gap electronic motor in which a stator and a rotor are arranged opposedly along the axis line direction of a rotor output shaft, the stator core, consisting of a laminated body formed by laminating a plurality of core sheets blanked from a metallic mother sheet in the radial direction, being formed into a trapezoidal shape the circumferential width of which increases gradually from the center of the rotor output shaft toward the outside, wherein a first cutting portion for forming a first side surface (first slot surface) in the circumferential direction of the core sheet, a second cutting portion for forming a second side surface (second slot surface) in the circumferential direction of the core sheet, a first moving means for reciprocatingly moving the first cutting portion, and a second moving means for reciprocatingly moving the second cutting portion are provided, andthe method comprises a first blanking step in which the first slot surfaces of the first to nth (n is a positive integer) core sheets are blanked in succession out of the mother sheet by moving the first cutting portion with predetermined intervals via the first moving means on the mother sheet; and a second blanking step in which the second slot surfaces of the first to nth (n is a positive integer) core sheets are blanked in succession out of the mother sheet by moving the second cutting portion with predetermined intervals via the second moving means.

2. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 1, wherein the first cutting portion and the second cutting portion are arranged opposedly so as to be brought close to each other or separated from each other.

3. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 1, wherein the first cutting portion and the second cutting portion move asynchronously.

4. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 1, wherein the first cutting portion is provided in a pair at the right and left with a predetermined clearance being provided therebetween, and the second cutting portion is arranged therebetween, whereby the first and second slot surfaces of two of the core sheets are blanked out of the mother sheet.

5. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 4, wherein the stator core is assembled in point symmetry by laminating the core sheets blanked out of the mother sheet along the radial direction.

6. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 1, wherein a third cutting portion for blanking the radial side surface (teeth surface) of the core sheet out of the mother sheet is further provided, and a third blanking step is provided to completely separate the core sheet from the mother sheet by means of the third cutting portion after the first and the second blanking steps.

7. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 1, wherein a pilot hole blanking step is further provided to form a pilot hole, which serves as a reference for the blanking steps, in the mother sheet.

8. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 6, wherein a concave/convex forming step is included between the second blanking step and the third blanking step to form a concave/convex portion for laminating and stakingly fixing the core sheets in a part of the core sheet.

9. The method for manufacturing a stator core for an axial air-gap electronic motor according to claim 6, wherein the core sheet is separated from the mother sheet in the third blanking step, and at the same time, is laminatedly fixed to the core sheet blanked before.