JP2001145288A - Rotor and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor which is provided with star-connected conductors, facilitates formation of its neutral point, and prevents a short circuit of windings. SOLUTION: In the rotor, a plurality of conductors 13 are starconnected. The conductors 13 separated from its neutral point are wound on tooth segments 9 from above twisted parts 15 as conductors near the neutral point, and coils 4 are formed. In the second insulated end portion 7b of a core, a pair of first protrusions 10 which forms an insulated u-shaped groove 10b for putting the twisted parts 15 in is formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotor for a motor, and more particularly, to a rotor in which coils are connected in a star shape, and a method of manufacturing the same.

[0002]

2. Description of the Related Art As a conventional motor rotor, there is a motor in which coils wound around a plurality of teeth pieces extending radially from a core (iron core) fixed to a rotating shaft are star-connected. That is, one end of each coil is connected to a commutator riser, and the other end of each coil is connected by soldering or welding, and that point is set as a neutral point.

As a method for manufacturing such a rotor, there is a method disclosed in Japanese Patent Application Laid-Open No. Hei 8-294253.
In this method, first, ends of three conductors are connected by soldering or welding to form a neutral point. In order to keep the conductor near the neutral point, in detail, put the conductor near the neutral point on the teeth piece, wind the conductor away from the neutral point from above, and neutralize Tie the nearby conductor to the tooth piece. Then, each end of the three wound conductors is connected to a commutator riser.

[0004] In this method, since the ends of the three conductors can be connected to form a neutral point without being related to the core, each conductor is wound around each tooth piece, and then the neutral point is formed. This operation is easier than connecting the parts to form a neutral point. In addition, since the conductive wire near the neutral point is wound around the tooth piece so as to be tied, no special member or a manufacturing process (lastly, resin bonding, etc.) is required to maintain the neutral point.

[0005]

However, in the above-mentioned method, the coating of the conductor near the neutral point may be destroyed by the heat during soldering or welding. Therefore, when the coating of the conductor on the side to be wound is peeled off due to friction or the like when winding the conductor near the neutral point and binding the teeth piece, the conductor near the neutral point and the neutral point are separated from the neutral point. There is a risk of short-circuiting with the conducting wire. As a result, there is a problem that the yield of the rotor is reduced.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and a rotor having a star connection and a method of manufacturing the same can easily form a neutral point of the rotor. An object of the present invention is to provide a rotor capable of preventing a short circuit of a wire and a method for manufacturing the rotor.

[0007]

According to a first aspect of the present invention, a plurality of conductors are connected in a star shape, and a conductor distant from the neutral point is wound around the core from above a conductor near the neutral point. In the rotor that is worn to form a coil, the core includes:
The gist of the present invention is that an insulating housing portion for housing at least the conductor near the neutral point is provided.

According to a second aspect of the present invention, in the rotor according to the first aspect, a plurality of radially extending teeth pieces for winding the conductive wire are formed on the core, and the axis of the core is formed on the core. An insulating portion for insulating the metal portion of the core and the conductive wire is provided on the direction end surface, and the accommodating portion is formed on the insulating portion so as to extend in the same direction as the teeth pieces. .

According to a third aspect of the present invention, in the rotor according to the second aspect, the accommodating portion is a groove formed by a pair of first convex portions projecting from the insulating portion. A pair of second convex portions that sandwich the conductor near the neutral point are formed higher than the first convex portion on the radially outer side of the core than one convex portion, and the conductor away from the neutral point is The gist of the invention is that the coil is formed by being wound radially inward of the core from the second convex portion.

The invention according to claim 4 is the invention according to claim 2 or 3.
The gist of the present invention is that the accommodating portions are formed on the insulating portions of the teeth pieces, respectively, and a conductor near the neutral point is accommodated in one of the plurality of accommodating portions.

According to a fifth aspect of the present invention, there is provided a rotor for forming a coil by winding a conductor near a neutral point formed by connecting a plurality of conductors in a star-shape and distant from the neutral point to a core. In the manufacturing method, after the conductor near the neutral point is housed in an insulating housing, the conductor is wound around the housing to form the coil.

According to a sixth aspect of the present invention, in the method for manufacturing a rotor according to the fifth aspect, a plurality of radially extending teeth pieces for winding the conductive wire are formed on the core. An insulating portion for insulating the metal portion of the core and the conductive wire is provided on the axial end surface of the core, and the conductive wire near the neutral point is provided on the insulating portion so as to extend in the same direction as the teeth piece. A pair of second projecting portions formed higher than the first projecting portions and radially outside the core from the pair of projecting first projecting portions, and a neutral point continuing from the second projecting portions. A coil is formed by housing a nearby conductive wire in the housing formed by the first convex portion, and winding a conductive wire away from the neutral point radially inward from the second convex portion. Is the gist.

According to the first aspect of the present invention, the conductor near the neutral point is accommodated in the insulating accommodating portion provided on the core, and the conductor separated from the neutral point from above is wound around the core. And a coil is formed. As a result, the conductor near the neutral point does not come into contact with the conductor away from the neutral point. Therefore, even if the coating of the conductor near the neutral point is broken when the neutral point is formed, a short circuit of the winding is prevented.

According to the second aspect of the present invention, the core is formed with a plurality of radially extending teeth pieces for winding a conductive wire, and the axial end face of the core is provided with a metal portion of the core. An insulating portion for insulating the conductive wire is provided. Then, the conductor near the neutral point is housed in a housing portion formed to extend in the same direction as the teeth piece in the insulating portion, and a wire away from the neutral point from above is wound around the core. A coil is formed.

According to the third aspect of the present invention, the conductor near the neutral point is sandwiched between the pair of second protrusions, and the conductor near the neutral point continuing from the second protrusion is connected to the pair of first protrusions. It is accommodated in the groove formed by the projection. And the conductor away from the neutral point is the second
The coil is formed by being wound radially inward of the core from the convex portion. Since the second convex portion is formed higher than the first convex portion, the pair of second convex portions prevents the coil from projecting outward in the radial direction of the core.

According to the fourth aspect of the present invention, the housing portions are respectively formed in the insulating portions of the teeth pieces. Therefore, the balance of the rotor is improved. Then, the conductor near the neutral point is housed in one of the plurality of housing sections.

According to the fifth aspect of the present invention, after the conductor near the neutral point is accommodated in the insulating accommodating portion, the conductor away from the neutral point is wound around the accommodating portion (core). A coil is formed. As a result, the conductor near the neutral point does not come into contact with the conductor away from the neutral point. Therefore, even if the coating of the conductor near the neutral point is broken when the neutral point is formed, a short circuit of the winding is prevented.

According to the present invention, the conductor near the neutral point is held by the second convex portion, and the conductor near the neutral point continuing from the second convex portion is connected to the first convex portion. Is accommodated in the accommodating part formed by. Then, a conductive wire distant from the neutral point is wound radially inward of the core from the second convex portion to form a coil. Since the second convex portion is formed higher than the first convex portion, the pair of second convex portions prevents the coil from projecting outward in the radial direction of the core.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS. FIG. 1 is a side view of a rotor (armature) of a DC motor. The rotor includes a rotating shaft 1, a core 2, a commutator 3, and a coil 4. A core 2 is fixed to an intermediate portion of the rotating shaft 1, and a commutator 3 is fixed to one end of the rotating shaft 1.

FIG. 2 is a perspective view of the rotor before the coil 4 is formed. FIG. 3 is a schematic front view of the rotor before the coil 4 is formed. FIG. 4 is a schematic longitudinal sectional view of the rotor before the coil 4 is formed. The core 2 includes a metal part 6 made of a laminated steel sheet in which a plurality of core sheets 5 are superimposed, and an insulating part 7 made of a resin for insulating the metal part 6 and the coil 4.

The metal part 6 includes a cylindrical part 8 in which the rotary shaft 1 is fitted.
a, and three metal teeth pieces 8b radially extending from the cylindrical portion 8a at equal angular (120 °) intervals. An extension 8c extending in the circumferential direction of the rotating shaft 1 is formed at the tip of the metal tooth piece 8b.

The insulating portion 7 includes first and second insulating end portions 7 formed so as to substantially cover axial end surfaces of the metal portion 6 respectively.
a, 7b and both insulating ends 7 except for the outer peripheral side of the extension 8c.
a, a slot insulating portion 7c for connecting the a and 7b in the axial direction;
There are first and second cylindrical portions 7d, 7e extending in the axial direction from the insulating ends 7a, 7b and internally fitting the rotating shaft 1. In the present embodiment, the metal piece 8b and the slot insulating portion 7c covering the metal piece 8b constitute the tooth piece 9.

A thin portion 7f for fixing the commutator 3 is formed in the first cylindrical portion 7d. In the second insulating end 7b,
A pair of first convex portions 10 and a pair of second convex portions 11 are formed for each tooth piece 9, that is, three pairs.

The second convex portion 11 is formed radially outside the second insulating end portion 7b so as to correspond to the tip of each tooth piece 9. The height of the second convex portion 11 is set so that the coil 4 wound around the teeth piece 9 does not protrude radially outward of the core 2 (see FIG. 7). A pair of second convex portions 11
Has an inclined surface, and a substantially V-shaped groove 11a is formed between both convex portions. The width of the V-shaped groove 11a is
The width becomes narrower toward the bottom, and the width at the bottom is set slightly smaller than the diameter of the bundled three conductors. Also, the second convex portion 11
As shown in FIG. 3, a tapered surface 11b is formed on one of the sides to increase the width of the V-shaped groove 11a toward the central axis of the core 2. V determined by the tapered surface 11b
The width of the groove 11a on the radially inner side of the core 2 is set to be slightly larger than the diameter of the bundle of three conductive wires.

The first convex portion 10 is formed on the second insulating end 7b.
It is formed so as to extend radially inward from the convex portion 11 in the same direction (radially) as the tooth pieces 9. This first convex portion 10
Is formed from the second convex portion 11 to the vicinity of the second cylindrical portion 7e. The height of the first convex portion 10 is set lower than the second convex portion 11 and higher than the diameter of the bundle of three conductive wires.
In addition, an inclined portion 10a is formed at the radially outer end of the first convex portion 10 as a high convex portion whose height becomes higher toward the radially outer side (see FIG. 7). The pair of first protrusions 10
A U-shaped groove 10 as a substantially U-shaped accommodating portion between the two convex portions.
b is formed. The width of the U-shaped groove 10b is set wider than the diameter of the bundle of three conductive wires.

The first insulating end 7a has the second convex 11
The same commutator-side convex portion 12 is similarly formed.
The coil 4 is formed by winding a conductive wire 13 around each tooth piece 9 and, as shown in FIG.
Are star-connected (Y-connected), and a neutral point 14 is formed. The conducting wire 13 near the neutral point 14 is twisted (twisted and bundled) to form a twisted portion 15.

As shown in FIG. 5 and FIG. 7, the neutral point 14 side of the twist portion 15 is
Near the bottom of a, it is held by the second convex portion 11. And
The twist portion 15 is housed in the U-shaped groove 10b of the first convex portion 10. Each of the conductive wires 13 branched from the twist portion 15 (away from the neutral point 14) is wound around the tooth piece 9 radially inside the second convex portion 11 to form the coil 4.

Here, the coil 4 formed on the tooth piece 9 holding the neutral point 14 is, as shown in FIGS. 6 and 7, from above the twist portion 15 housed in the U-shaped groove 10b. The conducting wire 13 is formed by winding.

The conductor 13 extending from the other end of each coil 4
As shown in FIG. 1, it is fixed to the riser 3a of the commutator 3. A method for manufacturing the rotor configured as described above will be described below.

First, one end of each of the three conductive wires 13 is twisted to form a twisted portion 15, and the ends thereof are connected by soldering or welding to form a neutral point 14. Next, as shown in FIG. 5 and FIG.
The pair of second convex portions 11 is pushed into the vicinity of the bottom of the V-shaped groove 11a, and is held by the second convex portions 11.

Next, the twist portion 15 is connected to the U of the first convex portion 10.
It is accommodated in the groove 10b. Next, each of the conductive wires 13 branched from the twist portion 15 (away from the neutral point 14) is wound around the tooth piece 9 radially inside the second convex portion 11 to form the coil 4. At this time, as shown in FIGS. 6 and 7, the tooth piece 9 holding the neutral point 14 has
The coil 4 is formed by winding the conducting wire 13 from above the twisted portion 15 housed in the U-shaped groove 10b.

Next, the conductor 1 extending from the other end of each coil 4
3 is fixed to a riser 3a of the commutator 3 as shown in FIG. The effects of the above embodiment will be described below.

(1) The twist portion 15 is housed in the U-shaped groove 10b of the first convex portion 10, and the twist portion 15
Is wound around the teeth piece 9 to form the coil 4. Thereby, the twist portion 15
Does not come into contact with the conductive wire 13 branched from the twist portion 15. Therefore, even if the coating of the twist portion 15 is broken when the neutral point 14 is formed, short circuit between the twist portion 15 and the coil 4 is prevented.

(2) Since the U-shaped groove 10b as the accommodation portion is formed integrally with the insulating portion 7, it is easily formed. (3) The pair of second convex portions 11 form a V-shaped groove 11a, and the neutral point 14 side of the twist portion 15 is held by the second convex portion 11 near the bottom of the V-shaped groove 11a. In addition, the second protrusion 11
Is formed higher than the first convex portion 10, and the conductive wire 13 is wound around the teeth piece 9 radially inside the second convex portion 11 to form the coil 4, so that the coil 4 projects outward in the radial direction of the core 2. This is prevented by the second projection 11. That is, the second convex portion 11 has a function of holding the neutral point 14 and the coil 4
Also has the function of preventing the core 2 from jumping out of the core 2 in the radial direction. Therefore, the shape of the insulating part 7 is simplified.

(4) The neutral point 14 is arranged radially outside the second convex portion 11, and the coil 4 is arranged radially inside the second convex portion 11. Therefore, contact between the neutral point 14 having no coating and the coil 4 is prevented, and the neutral point 14 and the coil 4 are not short-circuited.

(5) At the radially outer end of the first convex portion 10, an inclined portion 10 a whose height increases toward the second convex portion 11.
Was formed. Thereby, the height of the radially outer end of the first convex portion 10 increases, and the radially inner height of the first convex portion decreases. Therefore, while securing a wide space around which the conductive wire 13 is wound, the twisted portion 15 held near the bottom of the V-shaped groove 11a floats from the bottom until it contacts the bottom of the U-shaped groove 10b. , The inclined portion 10a can be accommodated in the U-shaped groove 10b. Moreover, V-shaped groove 1
Although the portion near 1a is likely to break the coating when the neutral point 14 is formed, the inclined portion 10a ensures that the coil 4 does not come into contact. Therefore, the twist portion 15 and the coil 4
Is prevented from being short-circuited.

(6) Since the first and second projections 10 and 11 are formed at positions corresponding to the teeth pieces 9 respectively, the balance of the rotor is improved. Therefore, unevenness of the rotation torque and the like are reduced.

(7) Since the neutral point 14 can be formed by connecting one end of each of the three conductors 13 without any relation to the core 2, the respective conductors are wound around each tooth piece. The work is easier than connecting the ends to form a neutral point.

The above embodiment may be modified and implemented as follows. In the above embodiment, the pair of first convex portions 10 forming the U-shaped groove 10b (accommodating portion) for accommodating the twisted portion 15 (the conducting wire near the neutral point 14) is provided, but at least the twisted portion is provided. If the twisted portion 15 can be accommodated, the U-shaped groove 10b may have another configuration if the twisted portion 15 and the conductive wire 13 do not come into contact with each other even if the conductive wire 13 is wound from above the twisted portion 15 is accommodated. Good. For example, a groove may be formed in the insulating portion 7 and the groove may be used as a housing portion. Even if you do this,
The short circuit between the twist portion 15 (the conductor near the neutral point 14) and the coil 4 is prevented. Also, for example, the first protrusion 10
Is formed radially outward from the second convex portion 11, and the neutral point 14 is formed.
May also be accommodated.

In the above embodiment, the first convex portion 10 is formed integrally with the insulating portion 7. However, the first convex portion 10 may be formed of another insulating member. Even in this case, the effect (1) of the above embodiment,
The same effects as (3) to (7) can be obtained.

In the above embodiment, the second convex portion 11
Although the V-shaped groove 11a is formed and is formed higher than the first convex portion 10 and has both the function of holding the neutral point 14 and the function of preventing the coil 4 from projecting outward in the radial direction of the core 2, , May be configured separately for each function. Even in this case, the effects (1), (2), (6), and
The same effect as (7) can be obtained.

In the above embodiment, the inclined portion 10 a is formed at the radially outer end of the first convex portion 10.
a may not be provided. Even in this case, effects similar to the effects (1) to (4), (6), and (7) of the above embodiment can be obtained.

In the above embodiment, the first and second convex portions 10 and 11 are formed at positions corresponding to the respective tooth pieces 9, but only one pair may be provided on one tooth piece 9. Good. Even in this case, effects similar to the effects (1) to (6) and (7) of the above embodiment can be obtained.

In the above embodiment, the conductor near the neutral point 14 is twisted to form the twisted portion 15.
It may not be twisted. In the above embodiment, the three coils 4 are embodied as a rotor connected in a Y-connection. However, a large number (for example, six) of coils may be embodied as a rotor connected in a star connection.

The technical ideas other than the claims that can be grasped from the above embodiments will be described below together with their effects. (A) The rotor according to claim 1, wherein the housing portion is formed on an insulating portion provided on a surface of the core and for insulating a metal portion of the core from the conductive wire. .

In this case, the insulating accommodating portion is formed integrally with the insulating portion for insulating the metal portion of the core from the conductive wire, so that it is easily formed. (B) In the rotor according to claim 2, the housing portion is a groove formed by a pair of first convex portions protruding from the insulating portion, and is radially larger than the first convex portion in the core. A rotor provided with a pair of second convex portions on the outer side for holding a conductor near the neutral point.

In this manner, the conductor near the neutral point is sandwiched between the pair of second protrusions, and the conductor near the neutral point continuing from the second protrusion is a groove formed by the pair of first protrusions. Housed within. Then, the conductor away from the neutral point is wound around the core from above.

(C) In the rotor according to any one of (3) and (4), the pair of second convex portions are formed of resin and have a substantially V-shaped V-shaped groove therebetween. The width of the bottom of the V-shaped groove is slightly smaller than the bundled diameter of the plurality of conductors. With this configuration, the portion of the conductor near the neutral point on the neutral point side is held near the bottom of the V-shaped groove.

(D) The rotor according to (c), wherein a high convex portion (10a) having a high height is formed at a radially outer end of the first convex portion. Child. In this case, the height of the radially outer end of the first convex portion increases, and the height of the first convex portion other than the radially outer end decreases. Therefore, while securing a large space around which the conductor is wound, the conductor near the neutral point held near the bottom of the V-shaped groove contacts the bottom of the groove formed by the first protrusion. Even if it floats from the bottom, it can be accommodated in the groove of the first convex part by the high convex part.

[0050]

As described above, according to the first to fourth aspects of the present invention, a neutral point can be easily formed in a rotor having a star connection. A rotor capable of preventing a short circuit of a winding can be provided. According to the fifth and sixth aspects of the present invention, in the method of manufacturing the rotor having the star connection, the neutral point can be easily formed and the short circuit of the winding can be prevented. A method for manufacturing a rotor can be provided.

[Brief description of the drawings]

FIG. 1 is a side view of a rotor according to an embodiment.

FIG. 2 is a perspective view of a rotor before a coil is formed.

FIG. 3 is a schematic front view of the rotor before a coil is formed.

FIG. 4 is a schematic longitudinal sectional view of a rotor before a coil is formed.

FIG. 5 is an explanatory diagram illustrating a rotor according to the embodiment.

FIG. 6 is a sectional view taken along the line AA of FIG. 5;

FIG. 7 is a schematic cross-sectional view of a main part for describing a rotor of the present embodiment.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Core, 4 ... Coil, 6 ... Metal part, 7 ... Insulation part, 9 ...
Teeth pieces, 10: first convex portion, 11: second convex portion, 13 ...
Conductor, 14: neutral point, 15: twisted portion, 10b: U-shaped groove.

Claims (6)

[Claims] A plurality of conductors (13) are star-connected, and a conductor (13) remote from a neutral point (14) is connected to the core (2) from above a conductor (15) near a neutral point. The core (2) is provided with an insulating accommodating part (A) for accommodating at least the conducting wire (15) near the neutral point (14). 1
0b). 2. The rotor according to claim 1, wherein the core (2) is formed with a plurality of radially extending teeth pieces (9) for winding the conductive wire (13),
An insulating portion (7) for insulating the metal portion (6) of the core (2) from the conductive wire (13) is provided on the axial end surface of the core (2). A rotor formed in the insulating portion (7) so as to extend in the same direction as the tooth pieces (9). 3. The rotor according to claim 2, wherein the housing portion (10b) is a groove formed by a pair of first convex portions (10) protruding from the insulating portion (7). A pair of second protrusions (11) for holding a conducting wire (15) near the neutral point (14) is radially outside the core (2) from the first protrusions (10). The conductor (13) formed higher than the first protrusion (10) and separated from the neutral point (14) is wound around the second protrusion (11) radially inward of the core (2). A rotor forming a coil (4). 4. The rotor according to claim 2, wherein the housing portions (10b) are respectively formed in the insulating portions (7) of the teeth pieces (9), and the plurality of housing portions (10b) are formed. 10b) includes a conductor (1) near the neutral point (14).
5) A rotor accommodating 5). 5. A neutral point (14) from above a conductor (15) near a neutral point (14) where a plurality of conductors (13) are star-connected.
In a method for manufacturing a rotor in which a conductor (13) distant from the core is wound around a core (2) to form a coil (4), the conductor (15) near the neutral point (14) is insulated by a housing. A method for manufacturing a rotor, comprising: winding the conducting wire (13) around the housing portion (10b) after forming the coil (4) after housing in the housing (10b). 6. The method for manufacturing a rotor according to claim 5, wherein a plurality of radially extending tooth pieces (9) for winding the conductive wire (13) are formed in the core (2). ,
An insulating portion (7) for insulating the metal portion (6) of the core (2) from the conductive wire (13) is provided on an axial end surface of the core (2), and the neutral point (14) The core (2) is formed by a pair of first convex portions (10) protruding from the insulating portion (7) so as to extend the nearby conducting wire (15) in the same direction as the tooth pieces (9).
A pair of second protrusions (11) formed higher than the first protrusions (10) on the outer side in the radial direction, and near a neutral point (14) continuing from the second protrusions (11). Is accommodated in the accommodating portion (10b) formed by the first convex portion (10), and the conducting wire (13) far from the neutral point (14) is accommodated in the second conductor (15).
A method for manufacturing a rotor, comprising forming the coil (4) by winding the coil (4) radially inward from the protrusion (11).