CN103762473A - Powder forming type carbon surface commutator and manufacturing process thereof - Google Patents
Powder forming type carbon surface commutator and manufacturing process thereof Download PDFInfo
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- CN103762473A CN103762473A CN201310754944.3A CN201310754944A CN103762473A CN 103762473 A CN103762473 A CN 103762473A CN 201310754944 A CN201310754944 A CN 201310754944A CN 103762473 A CN103762473 A CN 103762473A
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Abstract
The invention relates to a powder forming type carbon surface commutator and a manufacturing process thereof. The commutator comprises a carbon substrate, a main supporting body, middle filling bodies and hook-shaped commutation bars, wherein the carbon substrate is fixed to the inner side of the lower end of the main supporting body in an embedded mode, the middle filling bodies are arranged in the middle of the main supporting body, a plurality of copper sheets are evenly embedded into the upper end of the main supporting body in the circumferential direction, the hook-shaped commutation bars are erected on the copper sheets respectively, the lower end of each hook-shaped commutation bar is embedded into the carbon substrate, the gaps between the middle filling bodies and the copper sheets are filled with bakelite powder layers, the gaps between the middle filling bodies and the main supporting body are filled with bakelite powder layers, and the carbon substrate is formed in a compressing mode after graphite powder is added to the main supporting body and the hook-shaped commutation bars are wrapped in the carbon substrate at the same time. According to the powder forming type carbon surface commutator, the structure is exquisite, the welding step is omitted in the manufacturing process, cost is reduced, and the problem that the temperature is too high during motor rotor spot welding is solved by means of the assembly of the copper sheets and commutation sheets.
Description
Technical field
The present invention relates to commutator field, particularly relate to a kind of powder compacting carbon face commutator and manufacturing process thereof.
Background technology
Carbon commutator is with the corrosion-resistant and anti-wear performance of its excellence, is widely used in motor that common commutator cannot adapt to, and its structure mainly comprises by insulation support body, conductor part and carbon plate and forming.At present, the carbon plate of carbon commutator and conductive component be fixedly connected with general employing conductive adhesive, welding procedure or mosaic technology, wherein adopt conductive adhesive many.
But conducting resinl price is very expensive, cause the production cost of carbon commutator high, in addition, conductive glue adhesion is relatively poor, and is easily heated and comes unstuck, and heat resisting temperature is low, and useful life is short, and operating difficulties makes the quality stability of carbon commutator have hidden danger.
And welding procedure needs under special welding equipment and welding atmosphere just can weld, and technical process is more difficult, unreliable, the precious metal that its scolder adopts in addition, and price is very expensive, and scolder is preserved trouble, is not suitable for the large-scale production of carbon commutator.
If use in the gapless pressing-in commutator assembly of the carbon plate of moulding, accomplish that the carbon plate of manufactured goods is coordinated to precision with conductor part be very difficult in technique, cannot be applied in large-scale production.
Known manufacture method is first to make carbon plate and commutator assembly at present,
Seek to be again connected, due to the character of carbon plate, use bonding and welding procedure to be difficult to large-scale production, and the product obtaining is unsatisfactory, therefore, must seek other processes.
Summary of the invention
Technical problem to be solved by this invention is to provide a kind of powder compacting carbon face commutator and manufacturing process thereof, technique is simple, removed welding step, reduced cost, the problem of excess Temperature while utilizing the assembling of copper sheet and commutator segment to solve corresponding rotor spot welding.
The technical solution adopted for the present invention to solve the technical problems is: a kind of powder compacting carbon face commutator is provided, comprise carbon base body, main supporter, middle obturator and hook-type commutation bar, described carbon base body embeds the inner side, lower end that is fixed on main supporter, the intermediate arrangement of described main supporter has middle obturator, the upper end of described main supporter embeds some copper sheets is installed along even circumferential, the every added hook-type commutation bar that is provided with of copper sheet, the lower end of described hook-type commutation bar is embedded in carbon base body, in gap between described middle obturator and copper sheet and main supporter, be filled with bakelite bisque.
The top of described main supporter is the T shape post of vertically arranging along even circumferential, and between adjacent T shape post, inner side is connected with positioning step, and the medial surface of this positioning step has commutation bar location notch between two parties.
Between described T shape post, vertical inserting is embedded with copper sheet, and the lateral surface of this copper sheet flushes with the lateral surface of T shape post, and the upper surface of described copper sheet has locating notch between two parties, and the both sides vertical edge of this copper sheet is furnished with the flanging matching with T shape post.
The first half of described hook-type commutation bar is " n " shape, Lower Half is L-shaped, this n shape first half and L shaped Lower Half global formation the transiting rod by vertical layout are connected, the top of the described n shape first half is horizontal part, this horizontal part is embedded in the locating notch of copper sheet upper end, described transiting rod is embedded in commutation bar location notch, the bottom extension of described L shaped Lower Half is embedded in carbon base body, and the outside external part of described horizontal part is connected with the extension upper end, outside of oblique lower layout.
Described carbon base body is divided into the scallop with hook-type commutation bar equal number uniformly by some the insulation grooves by its center of circle, on described main supporter, also has breach with the corresponding position of insulation groove.
A manufacturing process for powder compacting carbon face commutator, its concrete manufacturing process is:
A: be copper sheet and hook-type commutation bar by the machine-shaping of copper raw material piece;
B: copper sheet and hook-type commutation bar surface are carried out Ultrasonic Cleaning and carry out zinc-plated;
C: with the compressing main supporter of phenolic moulding powder and middle obturator;
D: copper sheet and hook-type commutation bar are arranged in main supporter;
E: the main supporter arranging is transferred in particular manufacturing craft, graphite powder is poured in the lower end of main supporter and is pressed into pie, compacting is carried out at normal temperatures, and pressing pressure is 21 ± 3Mpa, pressurize 5 to 10 seconds, carbon base body and the hook-type bar that commutates is compressed together;
F: after carbon base body has been suppressed, pack middle obturator into, and in the gap between middle obturator and main supporter, the full phenolic moulding powder of filling forms bakelite bisque, then the temperature of 155～165 ℃, bakelite bisque is applied to the pressure of 23 ± 3Mpa, pressurize moulding in 5 to 10 seconds, bakelite bisque is separated adjacent hook-type commutation bar completely;
G: the commutator matrix that compacting is completed is placed in baking oven, sintering temperature is 38～241 ℃, sintering time is 12～13 hours, makes the bonding between carbon base body and bakelite bisque molecule more firm;
H: bore one in the center of middle obturator and carbon base body and connect upper and lower through hole;
I: milling insulation groove;
J: be up to the standards.
The component ratio of the graphite powder in further step e is, in mass fraction:
Base material powder: 60%
Tin bronze powder: 40%
Wherein base material powder formula is as follows
Graphous graphite powder 88%
It should be noted that phenolic resins is the synthetic plastic that thermal endurance, flame resistance, resistance to water and insulating properties are good, at high temperature its machinery and electric property are good, similar with the composition of phenolic moulding powder, can at high temperature spread with phenolic moulding powder, make carbon base body firmer, the bar that can firmly hook-type be commutated is fixed.
Further arranging is after graphite powder in step e joins in main supporter, then to adding in graphite powder the acetone of 20 parts as dispersant, all volatilizations of acetone in step f and g process.
Further setting is, after the graphite powder in step e joins in main supporter, also to add and have the zinc stearate of 0.1 part as release agent.
beneficial effect
The present invention relates to a kind of powder compacting carbon face commutator and manufacturing process thereof, commutator structure is simple, and copper sheet and hook-type commutation bar matches assembling one by one, and in gap, has filled up phenolic moulding powder, has guaranteed the insulating properties that adjacent copper sheet or hook-type commutate between bar; The problem of excess Temperature while utilizing the assembling of copper sheet and commutator segment to solve corresponding rotor spot welding; Hook-type commutation bar is embedded in carbon plate when carbon plate moulding, has saved welding or technique for sticking step; The carbon commutator finished product obtaining by this law; carbon plate is connected closely with conductive component and supporting mass; very close to each other; more than carbon plate tensile strength can reach 10N; and integrated artistic is simple, cost is low, and versatility is good; can apply and scale processing, and avoid the bonding and poor shortcoming of steady quality welding procedure in the past.
Accompanying drawing explanation
Fig. 1 is perspective view of the present invention;
Fig. 2 is the structural representation that partly cuts open of the present invention;
Fig. 3 is the schematic perspective view of main supporter of the present invention;
Fig. 4 is the schematic perspective view of copper sheet of the present invention;
Fig. 5 is the schematic perspective view of hook-type commutation bar of the present invention;
Fig. 6 is the structural representation of step e of the present invention;
Fig. 7 is the sintering temperature-time plot of step g of the present invention.
Embodiment
Below in conjunction with specific embodiment, further set forth the present invention.Should be understood that these embodiment are only not used in and limit the scope of the invention for the present invention is described.In addition should be understood that those skilled in the art can make various changes or modifications the present invention after having read the content of the present invention's instruction, these equivalent form of values fall within the application's appended claims limited range equally.
As shown in Fig. 1-7, embodiments of the present invention relate to a kind of powder compacting carbon face commutator and manufacturing process thereof, its structure comprises carbon base body 6, main supporter 1, middle obturator 4 and hook-type commutation bar 3, described carbon base body 6 embeds the inner side, lower end that is fixed on main supporter 1, the intermediate arrangement of described main supporter 1 has middle obturator 4, the upper end of described main supporter 1 embeds some copper sheets 2 is installed along even circumferential, the every added hook-type commutation bar 3 that is provided with of copper sheet 2, the lower end of described hook-type commutation bar 3 is embedded in carbon base body 6, in gap between described middle obturator 4 and copper sheet 2 and main supporter 1, be filled with bakelite bisque 7.
The top of described main supporter 1 is the T shape post 11 of vertically arranging along even circumferential, and between adjacent T shape post 11, inner side is connected with positioning step 12, and the medial surface of this positioning step 12 has commutation bar location notch 13 between two parties.
Between described T shape post 11, vertical inserting is embedded with copper sheet 2, and the lateral surface of this copper sheet 2 flushes with the lateral surface of T shape post 11, and the upper surface of described copper sheet 2 has locating notch 22 between two parties, and the both sides vertical edge of this copper sheet 2 is furnished with the flanging 21 matching with T shape post 11.
The first half of described hook-type commutation bar 3 is " n " shape, Lower Half is L-shaped, this n shape first half is connected with L shaped Lower Half global formation and by the transiting rod 33 of vertically arranging, the top of the described n shape first half is horizontal part 31, this horizontal part 31 is embedded in the locating notch 22 of copper sheet 2 upper ends, described transiting rod 33 is embedded in commutation bar location notch 13, the bottom extension 34 of described L shaped Lower Half is embedded in carbon base body 6, and the outside external part of described horizontal part 31 is connected with outside extension 32 upper ends of oblique lower layout.
Described carbon base body 6 is divided into the scallop with hook-type commutation bar 3 equal numbers uniformly by some the insulation grooves 5 by its center of circle, and position corresponding with insulation groove 5 on described main supporter 1 also has breach.
Embodiment 1:
A: get the copper sheet 2 of 8 and 8 hook-type commutation bars 3 of moulding, and copper sheet 2 and hook-type commutation bar 3 surfaces are carried out Ultrasonic Cleaning and carry out zinc-plated;
B: with the compressing main supporter 1 of phenolic moulding powder and middle obturator 4;
C: 8 copper sheets 2 and 8 hook-type commutation bars 3 are arranged in main supporter 1;
D: the main supporter 1 arranging is transferred in particular manufacturing craft, graphite powder is poured in the lower end of main supporter 1 and is pressed into pie, compacting is carried out at normal temperatures, and pressing pressure is 18Mpa, pressurize 10 seconds, carbon base body 6 is compressed together with hook-type commutation bar 3;
E: after carbon base body 6 has been suppressed, pack middle obturator 4 into, and in the gap between middle obturator 4 and main supporter 1, the full phenolic moulding powder of filling forms bakelite bisque 7, then the temperature of 155 ℃, bakelite bisque 7 is applied to the pressure of 20Mpa, pressurize moulding in 10 seconds, bakelite bisque 7 is separated adjacent hook-type commutation bar 3 completely;
F: the commutator matrix that compacting is completed is placed in baking oven, the temperature of sintering is shown in 38～241 ℃ and changes according to the Curves of Fig. 7, and sintering time is 12 hours, makes the bonding between carbon base body 6 and bakelite bisque 7 molecules more firm;
G: bore one in the center of middle obturator 4 and carbon base body 6 and connect upper and lower through hole;
H: milling insulation groove 5;
I: be up to the standards.
The component ratio of the graphite powder in step D is, in mass fraction:
Base material powder: 60%
Tin bronze powder: 40%
Wherein base material powder formula is as follows
Graphous graphite powder 88%
Phenolic resins 12%
Further arranging is after graphite powder in step D joins in main supporter 1, then to adding in graphite powder the acetone of 20 parts as dispersant, all volatilizations of acetone in step f and g process.
Further setting is, after the graphite powder in step D joins in main supporter 1, also to add and have the zinc stearate of 0.1 part as release agent.
A: get the copper sheet 2 of 12 and 12 hook-type commutation bars 3 of moulding, and copper sheet 2 and hook-type commutation bar 3 surfaces are carried out Ultrasonic Cleaning and carry out zinc-plated;
B: with the compressing main supporter 1 of phenolic moulding powder and middle obturator 4;
C: 12 copper sheets 2 and 12 hook-type commutation bars 3 are arranged in main supporter 1;
D: the main supporter 1 arranging is transferred in particular manufacturing craft, graphite powder is poured in the lower end of main supporter 1 and is pressed into pie, compacting is carried out at normal temperatures, and pressing pressure is 24Mpa, pressurize 10 seconds, carbon base body 6 is compressed together with hook-type commutation bar 3;
E: after carbon base body 6 has been suppressed, pack middle obturator 4 into, and in the gap between middle obturator 4 and main supporter 1, the full phenolic moulding powder of filling forms bakelite bisque 7, then the temperature of 165 ℃, bakelite bisque 7 is applied to the pressure of 26Mpa, pressurize moulding in 10 seconds, bakelite bisque 7 is separated adjacent hook-type commutation bar 3 completely;
F: the commutator matrix that compacting is completed is placed in baking oven, the temperature of sintering is shown in 38～241 ℃ and changes according to the Curves of Fig. 7, and sintering time is 12.5 hours, makes the bonding between carbon base body 6 and bakelite bisque 7 molecules more firm;
G: bore one in the center of middle obturator 4 and carbon base body 6 and connect upper and lower through hole;
H: milling insulation groove 5;
I: be up to the standards.
The component ratio of the graphite powder in step D is, in mass fraction:
Base material powder: 60%
Tin bronze powder: 40%
Wherein base material powder formula is as follows
Graphous graphite powder 88%
Phenolic resins 12%
Further arranging is after graphite powder in step D joins in main supporter 1, then to adding in graphite powder the acetone of 20 parts as dispersant, all volatilizations of acetone in step f and g process.
Further setting is, after the graphite powder in step D joins in main supporter 1, also to add and have the zinc stearate of 0.1 part as release agent.
Claims (9)
1. a powder compacting carbon face commutator, comprise carbon base body (6), main supporter (1), middle obturator (4) and hook-type commutation bar (3), described carbon base body (6) embeds the inner side, lower end that is fixed on main supporter (1), the intermediate arrangement of described main supporter (1) has middle obturator (4), it is characterized in that, the upper end of described main supporter (1) embeds some copper sheets (2) is installed along even circumferential, the added hook-type commutation bar (3) that is provided with of every copper sheet (2), the lower end of described hook-type commutation bar (3) is embedded in carbon base body (6), in gap between described middle obturator (4) and copper sheet (2) and main supporter (1), be filled with bakelite bisque (7).
2. a kind of powder compacting carbon face commutator according to claim 1, it is characterized in that: the T shape post (11) of the top of described main supporter (1) for vertically arranging along even circumferential, between adjacent T shape post (11), inner side is connected with positioning step (12), and the medial surface of this positioning step (12) has commutation bar location notch (13) between two parties.
3. a kind of powder compacting carbon face commutator according to claim 2, it is characterized in that: between described T shape post (11), vertical inserting is embedded with copper sheet (2), the lateral surface of this copper sheet (2) flushes with the lateral surface of T shape post (11), the upper surface of described copper sheet (2) has locating notch (22) between two parties, and the both sides vertical edge of this copper sheet (2) is furnished with the flanging (21) matching with T shape post (11).
4. a kind of powder compacting carbon face commutator according to claim 1, it is characterized in that: the first half of described hook-type commutation bar (3) is " n " shape, Lower Half is L-shaped, this n shape first half is connected with L shaped Lower Half global formation and by the transiting rod (33) of vertically arranging, the top of the described n shape first half is horizontal part (31), this horizontal part (31) is embedded in the locating notch (22) of copper sheet (2) upper end, described transiting rod (33) is embedded in commutation bar location notch (13), the bottom extension (34) of described L shaped Lower Half is embedded in carbon base body (6), the outside external part of described horizontal part (31) is connected with outside extension (32) upper end of oblique lower layout.
5. a kind of powder compacting carbon face commutator according to claim 1, it is characterized in that: described carbon base body (6) is divided into the scallop with hook-type commutation bar (3) equal number uniformly by some the insulation grooves (5) by its center of circle, and described main supporter (1) is upper also has breach with the corresponding position of groove (5) of insulating.
6. a manufacturing process for a kind of powder compacting carbon face commutator as claimed in claim 1, its concrete manufacturing process is:
A: be copper sheet (2) and hook-type commutation bar (3) by the machine-shaping of copper raw material piece;
B: copper sheet (2) and hook-type commutation bar (3) surface are carried out Ultrasonic Cleaning and carry out zinc-plated;
C: with the compressing main supporter of phenolic moulding powder (1) and middle obturator (4);
D: copper sheet (2) and hook-type commutation bar (3) are arranged in main supporter (1);
E: the main supporter (1) arranging is transferred in mould, graphite powder is poured into the carbon base body (6) that is pressed into pie in the lower end of main supporter (1), compacting is carried out at normal temperatures, pressing pressure is 21 ± 3Mpa, pressurize 5 to 10 seconds, carbon base body (6) is compressed together with hook-type commutation bar (3);
F: after carbon base body (6) has been suppressed, pack middle obturator (4) into, and in the gap between middle obturator (4) and main supporter (1), fill full phenolic moulding powder and form bakelite bisque (7), then the temperature of 155～165 ℃ to bakelite bisque
(7) apply the pressure of 23 ± 3Mpa, pressurize moulding in 5 to 10 seconds, bakelite bisque (7) is separated adjacent hook-type commutation bar (3) completely;
G: the commutator matrix that compacting is completed is placed in baking oven, sintering temperature is 38～241 ℃, sintering time is 12～13 hours, makes the bonding between carbon base body (6) and bakelite bisque (7) molecule more firm;
H: bore one in the center of middle obturator (4) and carbon base body (6) and connect upper and lower through hole;
I: milling insulation groove (5);
J: be up to the standards.
7. the manufacturing process of a kind of powder compacting carbon face commutator according to claim 6, is characterized in that, the component ratio of the graphite powder in step e is, in mass fraction:
Base material powder: 60%
Tin bronze powder: 40%
Wherein base material powder formula is as follows
Graphous graphite powder 88%
Phenolic resins 12%.
8. the manufacturing process of a kind of powder compacting carbon face commutator according to claim 6, it is characterized in that, after graphite powder in step e joins in main supporter (1), then to adding in graphite powder the acetone of 20 parts as dispersant, all volatilizations of acetone in step f and g process.
9. the manufacturing process of a kind of powder compacting carbon face commutator according to claim 6, is characterized in that, the graphite powder in step e also adds and has the zinc stearate of 0.1 part as release agent after joining in main supporter (1).
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| CN201310754944.3A CN103762473B (en) | 2013-12-31 | 2013-12-31 | A kind of powder compacting carbon face commutator and its manufacturing process |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107154570A (en) * | 2017-05-17 | 2017-09-12 | 薛伟 | A kind of commutator moulding process |
| CN107204557A (en) * | 2016-03-17 | 2017-09-26 | 德昌电机(深圳)有限公司 | The preparation method of commutator, the motor using the commutator and commutator |
| CN108832449A (en) * | 2018-06-05 | 2018-11-16 | 深圳市纳明特科技发展有限公司 | Motor diverter preparation process and motor diverter |
| CN112152034A (en) * | 2019-06-26 | 2020-12-29 | 宁波胜克换向器有限公司 | Combined commutator and production processing technology thereof |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101055962B (en) * | 2007-05-28 | 2010-08-04 | 史文浩 | Cylinder carbon commutator and its making method |
| DE102009057063A1 (en) * | 2009-12-04 | 2011-06-09 | Kolektor Group D.O.O. | Method for producing a flat commutator and flat commutator |
| CN203707536U (en) * | 2013-12-31 | 2014-07-09 | 宁波胜克换向器有限公司 | Powder forming carbon surface commutator |
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2013
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107204557A (en) * | 2016-03-17 | 2017-09-26 | 德昌电机(深圳)有限公司 | The preparation method of commutator, the motor using the commutator and commutator |
| CN107154570A (en) * | 2017-05-17 | 2017-09-12 | 薛伟 | A kind of commutator moulding process |
| CN108832449A (en) * | 2018-06-05 | 2018-11-16 | 深圳市纳明特科技发展有限公司 | Motor diverter preparation process and motor diverter |
| CN112152034A (en) * | 2019-06-26 | 2020-12-29 | 宁波胜克换向器有限公司 | Combined commutator and production processing technology thereof |
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