JP2002354735A - Rotor unit of direct-current brush motor and method for winding coil therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rotor unit of a direct-current brush motor, which can accomplish miniaturization of a coil and has the coil in which a wire is lap- wound over a plurality of teeth of a core, and a method for winding the coil. SOLUTION: The coil is manufactured by forming a plurality of lap-wound parts of the wire 1 in a circumferential direction in sequence. The lap-wound parts start from a hook 11a (the first joint) which is formed in one element (a) of a commutator 9, are introduced between the teeth A and L (between the first teeth) having the same phase as the hook 11a, have a part lap-wound over the three teeth A, B and C, are introduced from a part between the teeth A and B (between the second teeth), corresponding to a part between the teeth adjacent to a part between the teeth A and L, and terminate in a hook 11b (the second joint) formed in an element (b) having the same phase as the part between the teeth A and B.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotor unit constituting a rotating member of a DC brush motor and a method of winding a coil thereof, and more particularly to a type in which a wire is overlapped and wound over a plurality of teeth in a core. The present invention relates to a rotor unit having a coil and a method of winding the coil.

[0002]

2. Description of the Related Art Conventionally, as described in Japanese Patent Application Laid-Open No. 2000-60084, a rotor unit constituting a rotating member of a DC brush motor as shown in FIG. 6 has been known. As shown in FIG. 6, the rotor unit of such a DC brush motor is generally
A shaft 100 and a plurality of teeth A, B, fixed to the shaft 100 and radially extending in the radial direction;
A core 101 having C, D, E,...
A cylindrical commutator 102 fixed to the shaft 100 or the core 101 and arranged coaxially with the core 101 and composed of a plurality of (12) elements located in the circumferential direction.
And a coil 1 formed by a wire 103 wound around a commutator 102 and a core 101 according to a certain rule.
04. Here, commutator 102
Is not disposed within the axial length of the core 101, but is disposed at a position separated from the core 101 by a predetermined distance in the axial direction. In the outer peripheral portion of the commutator 102, Hooks b, c, d,... (Twelve hooks) for locking and joining the wire 103 are provided for each element.

The coil 10 in such a rotor unit
The method of winding the wire 103 of No. 4 will be described with reference to FIG. FIG. 7 is a diagram schematically showing a winding state of the wires 103 of the rotor unit according to the conventional technique shown in FIG. 6 (a developed view in a circumferential direction). Here, for convenience of explanation, FIG. In FIG. 6, only the state of winding of the main wire within the range actually seen is simply shown. In FIG. 7, the wire 103 starting from the hook a of the commutator is introduced between the teeth on the left side of the tooth A, and three teeth A, B,
After winding several times over C (only one is shown in FIG. 7), one winding unit (lap winding portion) that is drawn out from between teeth C and D and ends at hook b next to hook a Are formed (wound in the direction of the arrow in the figure), and this overlapped winding portion is successively arranged with one tooth (1
The wire 103 forms the coil 104 by being formed 12 times in a displaced manner.

[0004]

However, in such a rotor unit having a coil 104 of a type in which the wire 103 is wound over a plurality of teeth in the core 101, as shown in FIG.
When the coil 3 is wound, for example, a wire portion that is led out from between the teeth C and D and reaches the hook b and a wire portion that is introduced between the teeth B and C from the hook c cross each other (FIG. 7). ). In fact, these 12 Z points occur.)

[0005] As shown in FIG. 7, the phase in the circumferential direction of the hook, the circumferential phase between the teeth of the core 101 introduced from the hook, and the phase between the teeth of the core 101 guided to the hook are determined. This is because both phases in the circumferential direction are shifted. In other words, in FIG. 7, a wire portion derived from between the teeth (for example, between teeth C and D) and reaching the hook (for example, hook b) and between the hook (for example, hook c) and the teeth (for example, teeth B, This is due to the fact that the wire portion introduced between (C) does not exist in the vertical direction in FIG.

As described above, when the above-described intersection (point Z) occurs in the wire portion exchanged between the commutator and the core, at least the outer diameter of the wire itself at the intersection corresponds to the outer diameter of the coil. The volume occupied increases. Therefore, in the rotor unit in which the commutator 102 is disposed at a predetermined axial distance from the core 101 as shown in FIG. 6 described above, the wire exchanged between the commutator and the core Increasing the volume occupied by the coil in the portion is contrary to the demand for miniaturization of the DC brush motor as a whole.

[0007] As described in Japanese Patent Application Laid-Open No. 2001-86719, in a rotor unit of a type in which a commutator is arranged within the inner space of the core within the axial length of the core, a wire is connected to the commutator. A joint portion (corresponding to a hook in FIG. 6) for locking and joining to the shaft is formed on one (outer) end face in the axial direction of each element constituting the commutator. Therefore, in the rotor unit of this type, when the above-described intersection (point Z) is formed in the wire portion exchanged between the commutator and the core as described above, the intersection forms a commutator. Is formed on one (outside) end face (in the vicinity of the joint) of each element in the axial direction, and the coil height (the axial length occupied by the coil at least by the outer diameter of the wire itself at the intersection) Higher). Therefore, in the rotor unit of the type in which the commutator is disposed within the inner space of the core within the axial length of the core, due to the occurrence of the above-described intersection,
As a result, not only does the size of the DC brush motor as a whole be reduced, but also the length of the motor becomes shorter.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problem, and has been made to reduce the size of the coil in a rotor unit of a DC brush motor having a coil in which a wire is wound over a plurality of teeth in a core. It is a technical object to provide a rotor unit and a coil winding method for the rotor unit, which can achieve the above.

[0009]

In order to solve the above problems, the present invention provides a shaft, a core having a plurality of teeth fixed to the shaft and extending radially in a radial direction, and the shaft or the core. The teeth commencing from a cylindrical commutator composed of a plurality of elements located in the circumferential direction and coaxially arranged with the core, and a first joint part joined to one element of the commutator. A second joint portion which is introduced between the first teeth and has a portion wound and wound over a plurality of the teeth and is derived from between the second teeth of the teeth and joined to the element next to the one element A DC coil motor having a coil in which a plurality of superposed winding portions of wire are sequentially formed in a circumferential direction.
The space between the teeth is the space between the teeth next to the first teeth, the circumferential phase between the first joint and the first teeth, and the circumferential direction between the second joint and the second teeth. Have substantially the same phase.

[0010] According to the rotor unit of the DC brush motor according to the present invention, the overlapped winding portions of the wires sequentially formed in the coil in the circumferential direction are each formed from the first joint portion joined to one element of the commutator. Starting from the first joint, the first joint has a portion which is introduced between the first teeth having substantially the same circumferential direction and wound over a plurality of the teeth, and is between adjacent teeth between the first teeth. The process ends at the second joint portion, which is derived from between the second teeth and has substantially the same circumferential phase as that between the second teeth, joined to the element next to the one element. Therefore, the wire portions exchanged between the commutator and the core are all present in substantially the same phase plane in the circumferential direction, and the intersection (point Z) in the prior art as described above occurs. There is no. Therefore, according to the present invention, the volume occupied by the coil in the wire portion exchanged between the commutator and the core can be reduced by the amount that the intersection does not occur, and a demand for a reduction in the size of the coil, and furthermore, a DC brush It is possible to contribute to the demand for miniaturization of the motor as a whole. In addition, the above-mentioned wire wrapping portion has a “portion of being wrapped over a plurality of teeth”, and finally, the wire is wound between the second teeth, which is between the teeth next to the first teeth. May be derived, and in the “part that is wound over a plurality of teeth”, any of the teeth formed by the plurality of teeth may be wound over each other. In addition, the term "a plurality of lap winding portions are sequentially formed in the circumferential direction" means that a plurality of lap winding portions are formed in the circumferential direction as a result, and a process of winding the wire around the core. In the above, the order in the circumferential direction in which the overlapping winding portions are formed is arbitrary.

More preferably, the invention provides that the commutator has at least a portion located within the axial length of the core and the first and second joints are located on one end face of the commutator in the axial direction. It is good to apply to the rotor unit of the DC brush motor formed in the above. As described above, in the rotor unit of the type in which the first joint portion and the second joint portion are formed on one end surface in the axial direction of the commutator, the exchange is performed between the commutator and the core as described above. Intersection (Z point) as described above in the wire part
Is formed, the intersection is formed on one (outer) end face (in the vicinity of the first and second joints) in the axial direction of each element constituting the commutator. In, since the intersection is not formed, the coil height can be reduced by at least the outer diameter of the wire itself. Therefore, in the rotor unit of this type, by applying the present invention, it is possible to contribute not only to the demand for reducing the size of the coil but also to the demand for reducing the height of the coil.

More preferably, the lap portion of the wire is started from the first joint portion, introduced between the first teeth and wrapped a plurality of times over a predetermined plurality of teeth, and then between the first teeth and It is preferable to be wound once around a predetermined tooth sandwiched between the second teeth, to be drawn out from between the second teeth, and to end at the second joint.
According to this, the lap winding portion of the wire starts from the first joint portion, introduces the wire between the first teeth, and then simply laps a plurality of times over a predetermined plurality of teeth. Provided is a rotor unit of a DC brush motor which is more productive and inexpensive because it is constituted by a simple winding configuration in which a single winding is made around a predetermined tooth sandwiched between the teeth and the second tooth. It is possible to do.

[0013] Further, at least a part of the commutator is disposed within the axial length of the core, and a first joint and a second joint are formed on one end face of the commutator in the axial direction. In a rotor unit of a DC brush motor, as a winding method of the coil, first, a substantially cylindrical middle jig in which half of the number of elements of the commutator are arranged on one end surface in a circumferential direction. Prepare
The jig is arranged in the internal space of the commutator so that the phase of each hook is substantially at the center of the phase of each element adjacent to the commutator in the circumferential direction,
After making the lap winding portion of the wire by winding the wire in one rotation direction from the first joint portion to the second joint portion, the hook is positioned closest to the second joint portion. One rotation direction winding step of locking the wire, and winding the wire in the other rotation direction opposite to the one rotation direction from the second joint portion to the first joint portion of the overlapped winding portion of the wire. Then, alternately performing a winding step in the other rotation direction in which the wire is locked to the hook located at a position closest to the first joint portion, thereby sequentially winding the overlapped portions of the wire in the circumferential direction. After a plurality of the first bonding portions and the second bonding portion, the wire is bonded on one end face in the axial direction of the commutator at the plurality of first bonding portions and the second bonding portions. Around the hook radially inward from the joint 2 It is desirable to employ a method of cutting and removing the existing wire.

Normally, a wire is locked on the commutator side.
The hooks formed for joining as shown in FIG. 6 are necessary for the number of elements constituting the commutator. However, according to the coil winding method according to the present invention, the connection between each element of the commutator and the wire is performed on one end face in the axial direction of the commutator at a position different from the hook formed on the middle jig. It is performed at a certain first / second joint, and the hook of the intermediate jig is used only for positioning the wire for joining the wire at the first / second joint of each element of the commutator. Become. Then, in the process of locking the wire constituting the coil to the hook formed on the middle jig, the number of hooks formed on the middle jig is half the number of elements of the commutator. As shown in FIG. 6, the distance between the hooks is wider than when hooks for locking and joining the wires are required by the number of elements constituting the commutator, and the hooks are hooked up with an appropriate winding device. The degree of freedom is increased when the wire is locked to the wire, and the coil can be wound more easily and easily.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a rotor unit of a DC brush motor according to the present invention will be described below with reference to the drawings. First, referring to FIG. 1, one of the lap winding portions of a plurality of wires existing in the coil of the rotor unit according to the present invention is described.
One (one unit) is taken up and its configuration is briefly described.

FIG. 1 is a diagram schematically showing a winding condition of one (one unit) of a lap winding portion of a wire in a coil of a rotor unit according to the present invention (expanded view in a circumferential direction. Corresponding to the left-right direction). Here, an example is shown in which three teeth (a plurality of predetermined teeth) are overlapped and wound. The arrow in FIG. 1 indicates the winding direction of the wire 1.

In FIG. 1, a wire 1 starts from a first joint 3 joined to one of a plurality of elements a in a commutator 9 in a circumferential direction in a commutator 9. It is introduced between teeth (between first teeth) between a tooth A, which is one of a plurality of extending teeth, and a tooth present on the left side of the tooth A (not shown). Thereafter, the wire 1 is wrapped over three teeth A, B, and C. In FIG. 1, this lap winding is performed once for convenience of explanation, but is actually performed plural times (for example, 22 times). After being wound several times, the wire 1 becomes a tooth A (predetermined tooth)
, And is derived from between the teeth A and B (between the second teeth), and the second on the element b next to the element a
It is joined at the joint 5. As described above, one unit of the lap winding portion of the wire is constituted by the first joint portion 3 to the second joint portion 5.

It should be noted that in FIG. 1, the above-mentioned first teeth and the second teeth are between the mutually adjacent teeth, and the circumferential phase between the first joint 3 and the first teeth (see FIG. 1). 1) and the second position.
The circumferential phase (position in the left-right direction in FIG. 1) between the joint portion 5 and the second tooth is the same.
Therefore, the wire portion introduced from the first joint portion 3 toward the space between the first teeth and the second joint portion 5 from the space between the second teeth.
1 (the wire portion exchanged between the commutator 9 and the core 7) are all present in substantially the same phase plane in the circumferential direction (the vertical direction in FIG. 1). ), No intersection (corresponding to the point Z in FIG. 7) occurs in the wire portion exchanged between the commutator 9 and the core 7.

In the foregoing, the winding condition of one (one unit) of the lap winding portions of the wires in the coil of the rotor unit according to the present invention has been described with reference to FIG. In an actual rotor unit, the entire coil is formed by sequentially forming the overlapped portions of the wires shown in FIG. 1 in the circumferential direction. FIG. 2 shows the state of the winding of the entire coil.
Here, FIG. 2 shows a first embodiment of the winding condition of the entire coil in which three teeth are overlapped and wound on a rotor unit having 12 teeth and commutator elements in a 4-pole 4-brush DC motor. FIG. 1 is a diagram schematically showing the configuration (a development view in the circumferential direction; the circumferential direction corresponds to the left-right direction; a shaft is not shown). Note that FIG.
In the following drawings, components that are the same as or equivalent to those in FIG. 1 are denoted by the same reference numerals as those in FIG. 1, and duplicate descriptions are omitted.

In FIG. 2, as shown in FIG. 1, one unit of the lap winding portion of the wire starting from the first joint portion 3 and ending at the second joint portion 5 is sequentially formed at 12 places, and the coil is formed. The entire winding is formed. That is, the first lap winding portion starts from the hook 11a (first joint portion, in which the wire 1 is locked and joined) formed on a, which is one element of the commutator 9, and then the core 7 After being wound between the teeth L and A (between the first teeth) and being wound 22 times over three teeth A, B and C (a plurality of predetermined teeth) (once in FIG. 2), the tooth A (A predetermined tooth) is wound once, and is drawn out from between the teeth A and B (between the second teeth) and formed on the element b next to the element a of the commutator 9.
(The second joint).

The next lap winding section starts with the hook 11b, which was the second bonding section in the previous lap winding section, as the first bonding section, and is introduced between the teeth A and B (between the first teeth). After being wound 22 times over one of the teeth B, C, and D (predetermined plural teeth) (1 in FIG. 2)
Times), a hook is wound once around the tooth B (predetermined tooth), is drawn out from between the teeth B and C (between the second teeth), and is formed on the element c next to the element b of the commutator 9. 11c (second joint).
The wire 1 in the hook 11b may be cut or continuous.

As described above, the lap winding portion is sequentially formed, and the twelfth lap winding portion (the hook 11l is the first
The winding of the entire coil has been completed at the stage when the joint and the hook 11a are formed as the second joint. As described in the description of FIG. 1, no intersection (corresponding to the point Z in FIG. 7) occurs in the wire portion exchanged between the commutator 9 and the core 7 in FIG. In FIG. 2, the windings of the coils are all implemented in one rotation direction (in FIG. 2, counterclockwise direction). In the rotor unit in FIG. 2, hooks 11a to 11l for locking and joining the wire 1 are formed on each element of the commutator 9, and the commutator 9 is moved from the core 7 in the axial direction (vertical direction in FIG. 2). (The shaft is not shown.) Is assumed to be a rotor unit disposed at a position separated by a predetermined distance.

Next, referring to FIG. 3, for a four-pole, four-brush type DC motor, a rotor unit having 12 teeth and commutator elements has been wound with three teeth in an overlapping manner. A second embodiment will be described. FIG. 3 is a schematic diagram developed in the circumferential direction similarly to FIG. 2 (the shaft is not shown). The main difference between FIG. 3 and FIG. 2 is that at the stage of winding the wire 1, the number of elements of the commutator 9 is half (6
) Hooks 13a to 13f are arranged in the circumferential direction, and a substantially cylindrical middle jig (details will be described later with reference to FIG. 5) which is arranged in the internal space of the cylindrical commutator 9 is required. In the step of winding the wire 1, the winding directions of the twelve overlapping winding portions of the wire 1 are alternately counterclockwise (one rotation direction) and clockwise (other rotation direction), respectively. However, the commutator 9 has no members corresponding to the hooks 11a to 11l in FIG.
Are directly joined to the surface of each element of the commutator 9 (9a
1, 9b1, 9b2, etc.).

In FIG. 3, a rotor unit of a type in which the commutator 9 is disposed within the inner space of the core 7 within the length of the core 7 in the axial direction (up and down direction) is assumed. For convenience of explanation, it is described that the commutator 9 is disposed at a position separated from the core 7 by a predetermined distance in the axial direction (vertical direction)). Therefore, the joints (9a1, 9b1, 9b2, etc .; the first joint and the second joint) for joining the wire 1 to the commutator 9 are one of the components of the commutator 9 in the axial direction (in FIG. It is assumed that it is formed on the end face (upper side) (in FIG. 3, for convenience of description, a joint is formed on the outer peripheral surface of each element of the commutator 9). In FIG. 3, a cylindrical middle jig in which half of the number of hooks 13 a to 13 f (six) of the number of elements of the commutator 9 are arranged on the end face in the circumferential direction is the inside of the cylindrical commutator 9. It is assumed that they are arranged in space. In addition, the middle jig is arranged on the commutator 9 such that the phases of the hooks 13a to 13f in the circumferential direction are the centers of the phases of the elements a to l adjacent to the commutator 9.

In FIG. 3, as shown in FIG. 1, 12 units of a lap winding portion of the wire starting from the first joining portion 3 and ending at the second joining portion 5 are sequentially formed at 12 places, and the coil is formed. It is the same as FIG. 2 in that the entire winding is formed. However, there is a difference in the stage of winding the wire 1 as described below. First, the first lap winding portion starts from a joint 9a2 (first joint, to which the wire 1 is joined) formed on an end face of a, which is one element of the commutator 9, and then the core 7 is formed. Introduced between the teeth L and A (between the first teeth) of the three teeth A, B and C
After being wound 22 times (once in FIG. 3) over (a plurality of predetermined teeth), a tooth A (a predetermined tooth)
Is wound once, and is derived from between the teeth A and B (between the second teeth), and is formed on the end face of the element b next to the element a of the commutator 9 (the second bonding section 9b1). ), And so far is the same as FIG. The first lap winding portion is all wound in one rotation direction (counterclockwise direction in FIG. 3).

Next, as preparation for manufacturing the next (second) lap winding portion, the hooks 13a (the hooks closest to the second bonding portion) formed on the middle jig from the bonding portion 9b1 are prepared. Once wire 1 is locked, then wire 1
It is guided toward the joining portion 9c1 formed on the end face of the element c of the commutator 9, which is the starting point of the next overlapping winding portion. Here, the start point of the second overlapping winding part is not the element b of the commutator 9 but the element c.
This second lap winding portion is wound in the other rotation direction (clockwise direction in FIG. 3) opposite to the first lap winding portion, and the second joining portion 9 in FIG. This is because the start point and the first joint 3 are set as the end points of the winding.

That is, the second overlapped winding portion is formed by the joining portion 9c1 formed on the end face of the element c of the commutator 9.
(Second joint) and between teeth B and C (second
Between the teeth) and the teeth B (predetermined teeth)
Is wound clockwise once, and then wound clockwise 22 times (once in FIG. 3) over three teeth B, C, D (a plurality of predetermined teeth), and teeth A, It is derived from between B (between the first teeth) and ends at the joint 9b2 (first joint) formed on the element b of the commutator 9.

Next, in preparation for manufacturing the next (third) lap winding portion, the hook 13a (the hook closest to the first bonding portion) formed on the middle jig from the bonding portion 9b2 is prepared. Once wire 1 is locked, then wire 1
It is guided toward the joining portion 9c2 formed on the end face of the element c of the commutator 9, which is the starting point of the next lap winding portion.

The third lap winding is wound counterclockwise similarly to the first lap winding described above. In other words, the third lap winding portion has a configuration in which the first lap winding portion described above is shifted to the right by two elements in FIG. Joint 9d1 of commutator 9
It has become.

As described above, while the winding direction of the wire 1 is alternately switched between the counterclockwise direction (one rotation direction) and the clockwise direction (other rotation direction), the lap winding portions are sequentially formed. The twelfth lap winding portion wound clockwise (joining portion 9a1 is the second joining portion, joining portion 912
When the first joint is formed, the winding of the entire coil is completed. Although there are two joints on each element of the commutator 9, the wires 1 do not cross each other near the joints on the same element. Thereafter, a wire portion guided from the commutator 9 to the hook 13 of the middle jig (a wire portion in a range indicated by pp in FIG. 3).
Is cut and removed to complete the coil. As described in the description of FIG. 1, no intersection (corresponding to the point Z in FIG. 7) occurs in the wire portion exchanged between the commutator 9 and the core 7 in FIG. As a result, the intersection of the wires 1 does not occur on the end face of the commutator 9, so that the coil height can be reduced by the outer diameter of the wire 1.

The coil winding after performing the wire cutting operation described above with reference to FIG. 3 is the same as that shown in FIG. 2 (in each hook 11 formed on each element of commutator 9, wire 1 , When it is cut). In other words, in the process of winding the wire 1 in FIGS. 2 and 3, the winding direction, the necessity of the middle jig, and the like are different, but the winding mode of the completed coil is exactly the same. In the embodiment shown in FIG. 3 as well, 12 units of the lap winding portion of the wire starting from the first joint portion 3 and ending at the second joint portion 5 as shown in FIG. As a result, the winding of the entire coil is formed.

Next, a specific coil winding method will be briefly described with reference to FIGS. Here, FIG.
5 shows a coil winding method corresponding to the first embodiment shown in FIG. 2, and FIG. 5 shows a coil winding method corresponding to the second embodiment shown in FIG.

In FIG. 4, the present winding apparatus used in carrying out the present winding method includes a flyer 20 rotatable along a conical surface, which can supply the wire 1 from a tip end 20a.
And the fixing jigs 21 and 2 arranged at the positions shown in FIG. 4 with respect to the position where the core 7 and the commutator 9 (these are integrated, hereinafter referred to as “assembly”).
2a and 22b, and a cylindrical rotating jig 23 integrally fixed to the internal space in the cylindrical commutator 9. The rotational position of the assembly is controlled by controlling the rotation of the rotating jig 23. Fixing jig 21 and fixing jigs 22a, 22
2b are provided with gaps 24 and 25 as shown in FIG.
Can be introduced into the assembly only from the gaps 24 and 25. The position of the gaps 24 and 25 is set at an angle 90 for three teeth in the rotation direction of the core 7.
° is supported. Hereinafter, a method of winding a coil using the winding device will be described. In the assembly shown here, hooks 11a to 11l for locking and joining the wire 1 are formed on each element of the commutator 9 as described in the description of FIG. Are provided at a position separated from the core 7 by a predetermined distance in the axial direction (the direction perpendicular to the plane of FIG. 4; the shaft is not shown).

First, as shown in FIG. 4A, the rotation jig 23 is controlled to expose the gap A between the teeth A and L and the gap 24 between the teeth C and D so as to expose the core. 7 is rotated. In this state, the wire 1 is fixed to the hook 11a formed on the element a of the commutator 9, and the flyer 20 is moved from the position shown in FIG. 4A counterclockwise as viewed from above in FIG. Rotation is performed, and lap winding over three teeth A, B, and C is performed, and the flyer 20 is returned to the position shown in FIG.

Next, from this state, the rotating jig 23 is rotated 60 ° counterclockwise by two teeth and the flyer 20 is rotated counterclockwise as viewed from above in FIG. To the state shown in. In this state, between the teeth A and B is exposed in the gap 24.

Next, from this state, the rotating jig 23 is rotated 60 ° clockwise by two teeth and the flyer 20 is rotated counterclockwise as viewed from above in FIG. State as shown. By this step, it has been wound once around the tooth A.

Next, from this state, the rotating jig 23 is rotated counterclockwise by two teeth at 60 ° and the flyer 20 is rotated counterclockwise as viewed from above in FIG. By using the wire restricting device, the wire 1 is connected to the element b of the commutator 9.
While fixing to the hook 11b formed above, FIG.
To the state shown in. In this state, between the teeth A and B is exposed in the gap 24. By this step, the first overlapping winding portion is completed.

Next, from this state, the rotating jig 23 is rotated clockwise by 90 ° for three teeth and the flyer 20 is rotated counterclockwise as viewed from above in FIG. Move to the initial position of the winding step. That is, in this state, the teeth A,
B is exposed and the gap D is exposed between the teeth D and E. The rotating jig 23 is rotated counterclockwise by 30 ° for one tooth from the state shown in FIG. It has become. After that, FIG.
By repeating step (d) 12 times, the winding of the coil shown in FIG. 2 is completed. After the winding of the coil is completed, the wire 1 is joined at each hook 11 to complete the coil. Then, the assembly is removed from the winding device, and the assembly is integrated with a shaft (not shown) by a known method to complete the rotor unit.

Next, a coil winding method corresponding to the second embodiment shown in FIG. 3 will be described with reference to FIG. In FIG. 5, the present winding device used in performing the present winding method is the same as that in FIG. 4 described above. Also,
The cylindrical rotary jig 23 in FIG. 4 corresponds to the cylindrical middle jig 23 in FIG. Column-shaped jig 2
3 has six hooks 13a to 13f on its end face in the circumferential direction.
The hooks 13a to 13f are arranged so that the circumferential phase of the hooks 13a to 13f is at the center of the phase of each element a to l of the commutator 9.

First, as shown in FIG.
3, the teeth A and L are exposed in the gap 25,
The core 7 is rotated to a position where the teeth C and D are exposed in the gap 24. In this state, the wire 1 is fixed to the hook 13f formed on the middle jig 23, and the flyer 20 is moved to the position shown in FIG.
From the position shown in FIG. 5 (a), the three teeth A, B,
C, and the flyer 20 is moved again as shown in FIG.
Return to the position shown in (a).

Next, from this state, the middle jig 23 is rotated counterclockwise by two teeth at 60 ° for 60 ° and the flyer 20 is rotated counterclockwise when viewed from above in FIG. To the state shown in. In this state,
In the gap 24, the space between the teeth A and B is exposed.

Next, from this state, the rotating jig 23 is rotated clockwise by 2 teeth 60 ° for two teeth, and the flyer 20 is rotated counterclockwise as viewed from above in FIG. State as shown. By this step, it has been wound once around the tooth A.

Next, from this state, the rotating jig 23 is rotated counterclockwise by 30 ° for one tooth and the flyer 20 is rotated counterclockwise when viewed from above in FIG. By using the wire restricting device, the wire 1 is fixed to the hook 13a formed on the middle jig 23, and the state shown in FIG. In this state, between the teeth B and C is exposed in the gap 24. By this step, the first overlapping winding portion is completed (one-turn direction winding step).

Next, from this state, a process for winding the next second overlapping portion is started. In the second winding step, it is necessary to wind the wire 1 in a direction opposite to that of the first overlapped winding portion. Therefore, the state shown in FIG. The steps of FIGS. 5A to 5D, which are the steps of winding the first overlapped winding section described above, may be performed in the reverse order (winding step in the other rotation direction). A detailed description of this step is omitted. Thereafter, the winding process of the coil shown in FIG. 3 is completed by repeating the above-described winding process in one rotation direction and the winding process in the other rotation direction six times in a set. According to this method, the number of hooks may be halved as compared with the case where hooks for locking and joining wires are required by the number of elements constituting the commutator as shown in FIG. The distance between them becomes wider, and the degree of freedom in locking the wire to the hook with an appropriate winding device is increased, so that the coil can be wound more easily and easily.

After the winding of the coil is completed, the wires 1 are joined at the joints 9a2, 9b1 and the like on the end face of the commutator 9, and then guided from the commutator 9 to the hook 13 of the middle jig 23. The coil is completed by cutting and removing the wire portion that is present. Then, the assembly is removed from the winding device, and the assembly is integrated with a shaft (not shown) by a known method to complete the rotor unit.

As described above, the embodiment according to the present invention will be described.
In the four-pole, four-brush type DC motor, a case where the number of teeth and the number of elements of the commutator are 12 and the rotor unit has 12 teeth has been described as an example, but the present invention is not limited to this. Not to mention that it is not.

[0047]

As described above, according to the present invention,
In a rotor unit of a DC brush motor having a coil of a type in which a wire is wound over a plurality of teeth in a core, it is possible to provide a rotor unit capable of achieving downsizing of the coil and a method of winding the coil. Become.

[Brief description of the drawings]

FIG. 1 is a diagram schematically showing a winding condition of one (one unit) of a lap winding portion of a wire in a coil of a rotor unit according to the present invention.

FIG. 2 is a diagram schematically showing a first embodiment of a winding condition of an entire coil in which three teeth are overlapped and wound;

FIG. 3 is a diagram schematically illustrating a second embodiment of the winding condition of the entire coil in which three teeth are overlapped and wound.

FIG. 4 is a diagram showing a coil winding method corresponding to the first embodiment shown in FIG. 2;

FIG. 5 is a view showing a coil winding method corresponding to the second embodiment shown in FIG. 3;

FIG. 6 is a rotor unit constituting a rotating member of a DC brush motor according to the related art.

FIG. 7 is a diagram schematically illustrating a winding state of wires of the rotor unit according to the related art illustrated in FIG. 6;

[Explanation of symbols]

 Reference Signs List 1 wire 3 first joint 5 second joint 7 core 9 commutator 9a to 9l joint (first joint, second joint) 11 hook (first joint, second joint) 13 middle jig Hook 23 jig

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 5H603 AA09 BB04 BB12 CA05 CB02 CB04 CC03 CC17 CD05 CD21 CE01 5H604 AA08 BB01 BB07 BB14 CC02 CC05 CC13 QB01 5H615 AA01 BB01 BB04 BB14 PP02 PP12 PP14 QQ02 QQ19 A01A11 A11H11A

Claims (4)

[Claims] 1. A shaft, a core fixed to the shaft and having a plurality of teeth radially extending, and fixed to the shaft or the core and arranged coaxially with the core. A cylindrical commutator composed of a plurality of elements located in a circumferential direction, and a first joint portion joined to one element of the commutator, which is introduced between the first teeth of the teeth and spans a plurality of the teeth. A plurality of wrapped portions of the wire are formed sequentially in the circumferential direction, having a portion to be wrapped and ending at a second joint portion which is drawn out from between the second teeth of the teeth and joined to an element next to the one element. The rotor unit of the DC brush motor having
The space between the teeth is the space between the teeth next to the first teeth, the circumferential phase between the first joint and the first teeth, and the circumferential direction between the second joint and the second teeth. Wherein the phases are substantially the same. 2. The commutator according to claim 1, wherein at least a part of the commutator is disposed within an axial length of the core, and the first joint and the second joint are one of the axial parts of the commutator. A rotor unit for a DC brush motor, wherein the rotor unit is formed on an end surface of the rotor. 3. The wrap portion of the wire according to claim 1, wherein the wrap portion of the wire starts from the first joint portion, is introduced between the first teeth, and is wrapped a plurality of times over a predetermined plurality of the teeth. Thereafter, the coil is wound once around a predetermined tooth sandwiched between the first teeth and the second teeth, and is derived from between the second teeth and ends at the second joint. Brush motor rotor unit. 4. The method of winding a coil of a rotor unit of a DC brush motor according to claim 2, wherein half of the number of elements of the commutator are arranged on one end face in a circumferential direction. A cylindrical jig is arranged in the internal space of the commutator such that the phase of each hook in the circumferential direction is substantially the center of the phase of each element adjacent to the commutator, and the wrapped portion of the wire is First
After winding by winding the wire in one rotation direction from the joint to the second joint, one-turn winding in which the wire is locked to the hook closest to the second joint. Step and after producing the lap winding portion of the wire by winding the wire in the other rotation direction opposite to the one rotation direction from the second bonding portion toward the first bonding portion,
After alternately forming a plurality of overlapping winding portions of the wire in the circumferential direction by alternately performing the other rotation direction winding step of locking the wire to the hook at the position closest to the first joint portion, The wires are joined on one end face in the axial direction of the commutator at a plurality of the first joints and the second joints, and the wire is radially inner than the plurality of the first joints and the second joints. A method of winding the coil of a rotor unit of a DC brush motor, wherein a wire existing around a hook is cut and removed.