【０００１】
【発明の属する技術分野】
この発明は、直流電動機に用いられる回転電機用整流子装置に関し、特に整流子片と電機子コイル導体が超音波溶接により接続された回転電機用整流子装置に関する。
【０００２】
【従来の技術】
この発明で回転電機用整流子装置とは、回転電機の電機子コイル導体の口出部が接続された整流子を意味する。
【０００３】
従来の回転電機用整流子装置は、整流子片と電機子コイル導体とを超音波溶接法を用いて接続しており、回転子は、電機子と整流子がシャフトに同軸上に圧入固定されている。電機子は、外縁部付近の円周方向に複数のスロットを有する積層鉄心と、積層鉄心と同じ位置にスロットを有する端板と、積層鉄心および端板が圧入固定されたシャフトと、積層鉄心および端板のスロットを貫通し、Ｕ字型に形成された電機子コイル導体とからなる。
【０００４】
整流子は、円筒状に並べられた複数の鞍状の整流子片と、整流子片をインサートとして固定した円筒状整流子胴とからなり、整流子胴はシャフトに圧入固定されている。鞍状の整流子片の長手方向の寸法のバラツキを吸収するため、整流子胴の軸方向の寸法が整流子片の長手方向の寸法はより長くなっていて、整流子胴の上下の端部には樹脂が整流子片の整流子面から外側に飛び出ている。
【０００５】
電機子コイル導体は丸形断面形状の銅線を絶縁皮膜で被覆されていて、電機子のスリットに挿入されるようにＵ字型に成形されている。電機子コイルから整流子へと引き出し方向に引き出された電機子コイル導体の両端からなる口出部は、絶縁皮膜だけを切削加工等で取り除かれている。超音波溶接機を用いて、超音波ホーンで押さえつけながら、口出部を整流子片の端部に溶接している（例えば、特許文献１参照。）。
【０００６】
【特許文献１】
特開平１１−２９９１５４号公報 （段落０００５、第１１図）
【０００７】
【発明が解決しようとする課題】
しかし、上述のような回転電機用整流子装置では以下のような問題があった。
整流子片をインサートとしてインサートモールドで整流子胴に一体に成形しているので、整流子片の整流子面が整流子胴の端部より少し凹んだ形状になっている。また、インサートモールドの金型と整流子片とのクリアランスが少し大きくなると、樹脂のバリが整流子片の外面に出っ張ることがある。このような整流子片に口出部を超音波溶接すると、導体の一部が出っ張った樹脂に当たり、整流子片と口出部の接続面の接続面積が少なくなる。また樹脂のバリが接続面に介在すると極端に強度が落ちることがある。
【０００８】
また、電機子コイル導体の引き出し方向である、電機子コイルから整流子へ引き出した丸形断面の口出部を平面な整流子片へ溶接するために、引き出し方向に対して前方に位置する接続面の前縁部分は口出部の端面で縁取られるが、引き出し方向に対して後方に位置する後縁部分は尖った形状である。このような接続面に電機子コイル導体への通電で、電機子コイル導体が発熱し、電機子コイル導体が熱膨張することによる応力と、電機子が回転し、電機子コイル導体の端板と接続面の後縁間の自重による応力が接続面に加わる。特に、尖った後縁部分に応力が集中することで、接続面の接合強度が機械的疲労で低下する可能性があった。
【０００９】
この発明の目的は、電機子コイル導体と整流子片との間の接続面に力が加えられたときに力の集中を防ぐようにした回転電機用整流子装置を提供することである。
【００１０】
【課題を解決するための手段】
この発明に係わる回転電機用整流子装置においては、電機子回転軸に取り付けられた電気絶縁性の整流子胴と、整流子胴に支持された複数の整流子片と、電機子コイルから引き出し方向に引き出されて整流子片に接続された口出部とを備え、口出部と整流子片との間の接続面が引き出し方向に対して後方に位置する後縁部分を有する回転電機用整流子装置において、接続面の後縁部分が、引き出し方向に対してほぼ直角に延びた直線状であり、もって口出部に加えられる接続から引き剥がそうとする力を後縁部分に沿って分散させる。
【００１１】
また、回転電機用整流子装置は、整流子面を有する複数の整流子片と、上記整流子面に無段差な外周面を有し、上記整流子片が外周部に埋設された円筒状の整流子胴と、口出部が上記整流子片に接続された電機子コイル導体とを備えた回転電機用整流子装置において、上記整流子片と上記口出部との間の互いの接続面の外縁に、上記口出部の端面から離間し、上記端面に平行な辺が含まれているようにしたものである。
【００１２】
【発明の実施の形態】
実施の形態１．
図１は本発明による実施の形態１の回転電機用整流子装置を用いた回転子の断面図である。図２は図１での整流子片と導体の接続状態を示す平面図である。
電機子１は、外縁部付近の円周方向に複数のスロットを有する積層鉄心２と、積層鉄心２と同じ位置にスロットを有する端板３と、積層鉄心２および端板３が圧入固定されたシャフト４と、積層鉄心２および端板３のスロットを貫通し、Ｕ字型に形成された電機子コイル導体５とからなる。
【００１３】
整流子６は、銅製の、円筒状に並べられた複数の鞍状の整流子片７と、整流子片７をインサートとして固定した円筒状の整流子胴８とを備え、整流子胴８はシャフト４に圧入固定されていて整流子６は全体として円筒体をなしている。整流子胴８の外周部９は整流子片７に覆われた部分と整流子胴８の樹脂が表面にでた外周面１０とを備えている。
【００１４】
整流子６は、またインサートモールド法で製造され、インサートは、整流子６の１個分の複数の整流子片７を一部分の箇所を連結した円筒状の部材を用いている。この円筒状の部材は銅板を冷間鍛造法で加工して製作している。円筒状の部材の内周面に凸状の突起を設けて、整流子片７と整流子胴８との結合力を確保している。この円筒状の部材をインサートモールド金型にセットし、フェノール樹脂で成形した後、外周を切削すると、連結していた箇所が切削されて、整流子片７は個片の分かれて、整流子面１１が外周面１０と無段差に配列された整流子片７が外周部９に埋設された円筒状の整流子６が出来上がる。円筒状の軸を中心として、円柱状の孔１２が設けられている。整流子６はさらに、シャフト４に挿入されて電機子１と対向する底面１３に接する外周面１０と整流子面１１を切削加工で境界線１４を境とした整流子面１１より約０．５ｍｍ凹んだリング状の周方向の段差部１５が設けられる。整流子片７の長さのばらつきや金型へのセットの際の位置ずれなどにより、整流子片７の端部の位置はばらついているので、整流子片７の端部の一部も含んだ段差部１５が設けてある。
【００１５】
電機子コイル導体５は丸形断面形状を有する直径約２ｍｍの銅線１６の外周部を絶縁皮膜１７で被覆されている導体をＵ字型に成形したもので、電機子１から整流子６への引き出し方向に引き出された電機子コイル導体５の両端を口出部１８に加工してある。口出部１８は絶縁皮膜１７だけを切削加工等で取り除いてある。１個の整流子片７には結線の関係から２本の口出部１８を上下に重ねて接続される。整流子片７と口出部１８との接続は超音波溶接法で、銅線１６と整流子片７との間で溶接を行う。口出部１８を超音波ホーンで押さえられながら、超音波振動を整流子片７と銅線１６および銅線１６同士の界面に加えて溶接する。超音波ホーンを境界線１４を含むような口出部１８の位置に合わせて振動を加える。このようにして口出部１８と整流子片７との間には接続面１９が形成され、この接続面１９は口出部１８の引き出し方向に見て後方となる位置に境界線１４によって形成された後縁部分である辺２０を備えている。この後縁部分即ち辺２０は周方向に延びた直線状のものである。この辺２０は口出部１８の端面２１平行で、接続面１９は矩形であった。
【００１６】
このように溶接された整流子片７と２本の銅線１６の剥離強度を測定すると、約１０％向上していて、バラツキも約６割に減少した。特に境界線１４上の辺２０は従来のような細長い楕円の長手方向の円弧のような狭い接続面でないので、電機子１側から整流子６側へ電機子コイル導体５を引きはがす剥離強度が大きくなっている。
【００１７】
さらに、この発明の回転電機用整流子装置を用いた回転電動機を繰り返し駆動した後で接続箇所を観察すると、従来品は細長い楕円の長手方向の円弧の先端部分に亀裂が入っているものが見られたが、実施の形態１では改善された。
【００１８】
このような整流子片７と電機子コイル導体５とが接続された回転電機用整流子装置では、段差部１５を整流子片７の端部に設けられ、整流子面１１と段差部１５の境界線１４を含んで溶接した結果、溶接面１９の形状が矩形になって剥離強度が大きくなった。
【００１９】
さらに、導体５が外周面１０ａに当らないので、超音波ホーンから導体５に加えた力が逃げてしまうことがなく、均一な溶接ができる。
【００２０】
さらに、段差部１５を切削加工で形成する際に、段差部１５に這え上がるフェノール樹脂のバリを同時に除去することで、接続面１９にバリなどが介在することがなく、剥離強度のばらつきが小さくなる。
【００２１】
実施の形態２．
図３はこの発明の実施の形態２の回転電機用整流子装置の部分断面図であり、図４は図３で用いた接触子片の斜視図である。
実施の形態１とは整流子片２２の端部２２ａに整流子面２３より、外側に飛び出た溶接部２４を有した矩形の突起部２５を設けたことが異なっている。
【００２２】
整流子２６は実施の形態１と同様にして製作することができる。整流子２６は、またインサートモールド法で製造され、インサートは、整流子２６の１個分の複数の整流子片２２を一部分の箇所を連結した円筒状の部材を用いている。この円筒状の部材は銅板を冷間鍛造法で加工して製作している。円筒状の部材の内周面に凸状の突起を設けて、整流子片２２と整流子胴２７との結合力を確保している。この円筒状の部材をインサートモールド金型にセットし、フェノール樹脂で成形した後、外周を切削すると、連結していた箇所が切削されて、整流子片２２は個片に分かれて、整流子面２３が外周面２８と無段差に配列された整流子片２２が外周部２９に埋設された円筒状の整流子２６が出来上がる。この切削の際に径方向の切削量を０．３ｍｍ少なくして、溶接部２４を作製してある。
【００２３】
このようにして得られた整流子２６の整流子片２２の突起部２５に実施の形態１と同様に超音波溶接法で口出部１８の絶縁皮膜１７を剥離した銅線１６を溶接する。超音波ホーンを整流子片２２の突起部２５をすべてカバーするような形状にして溶接した。
【００２４】
このように溶接して接続された整流子片２２と銅線１６および銅線１６間の接続面３０は、整流子片２２の突起部２５の溶接部２４の形状とほぼ等しく矩形であり、接続面３０の口出部１８の引き出し方向に対して後方に位置する後縁部分である辺３１は口出部１８の端面２１と平行な線分であった。
【００２５】
また剥離強度を初期と回転電動機に組み込んで駆動後とを測定したが、実施の形態１とほぼ同じ値であった。
【００２６】
このようなこの発明の実施の形態２の回転電機用整流子装置は実施の形態１と同様に剥離強度が向上する。
【００２７】
さらに突起部２５の溶接部２４が飛び出ているので、超音波ホーンを突起部２５の溶接部２４と平行に当たるように調整して溶接することで、接続面３０内の剥離強度は均一になる。
【００２８】
実施の形態３．
図５はこの発明の実施の形態３の回転電機用整流子装置の部分断面図であり、図６は図５で用いる電機子コイル導体の口出部の斜視図である。
電機子コイル導体５の口出部３２の端面３３から所望の長さに渡って円柱部３４を設けてある。円柱部３４に連なって、その円断面に接辺を含む窪み３５をダイスで加工して設けてある。この加工作業は、銅線１６の絶縁皮膜１７を剥がす作業と同時に行われる。
【００２９】
このように加工された口出部３２を実施の形態１と同様に超音波溶接で整流子片３６に接続する。このとき口出部３２の窪み３５が整流子胴３７の外周面端部３８と当たらないようにして、円柱部３４と窪み３５の境界線３９が整流子片３６上にくるように位置合わせしている。
【００３０】
このように溶接して接続された整流子片３６と銅線１６および銅線１６間の接続面４０の口出部３２の引き出し方向に対して後方に位置する後縁部分である外縁に境界線３９上の辺４１が見られ、辺４１は口出部３２の端面３３と平行であった。
【００３１】
そこで、整流子片３６と銅線１６間の剥離強度を初期と回転電動機に組み込んで駆動後とを測定したが、実施の形態１とほぼ同じ値であった。
【００３２】
このようなこの発明の実施の形態３の回転電機用整流子装置は実施の形態１と同様に剥離強度が向上する。
【００３３】
さらに、銅線の絶縁皮膜の剥離作業と同時に窪みの加工を行うことで、新たな工数が掛からない。
【００３４】
さらに、整流子胴側の加工は従来通りでいいので、新たなインジェクションモールド金型等を準備しなくても済む。
【００３５】
【発明の効果】
以上の如くこの発明の回転電機用整流子装置による効果は次の通りである。
（１）回転電機用整流子装置は、電機子回転軸に取り付けられた電気絶縁性の整流子胴と、整流子胴に支持された複数の整流子片と、電機子コイルから引き出し方向に引き出されて整流子片に接続された口出部とを備え、口出部と整流子片との間の接続面が引き出し方向に対して後方に位置する後縁部分を有する回転電機用整流子装置において、接続面の後縁部分が、引き出し方向に対してほぼ直角に延びた直線状であり、もって口出部に加えられる接続から引き剥がそうとする力を後縁部分に沿って分散させるので、電機子コイル導体を電機子側から整流子側へ引っ張って、口出部と整流子片との間のお互いの接続面に加わる応力が生じた場合、応力に対して垂直な辺でその応力を受けるので、接続面の辺の単位長さ当たりの応力が小さく、電機子コイル導体が整流子片から剥離する危険が少なくなる。
【００３６】
（２）回転電機用整流子装置は、整流子面を有する複数の整流子片と、整流子面に無段差な外周面を有し、整流子片が外周部に埋設された円筒状の整流子胴と、口出部が整流子片に接続された電機子コイル導体とを備えた回転電機用整流子装置において、整流子片と口出部との間の互いの接続面の外縁に、口出部の端面から離間し、端面に平行な辺が含まれているので、整流子片と電機子コイル導体との溶接面が矩形になり、電機子コイル導体の形状や整流子片への当たり方などが溶接強度への影響を除外できる。
【図面の簡単な説明】
【図１】この発明の実施の形態１の回転電機用整流子装置を用いた回転体の断面図である。
【図２】図１の整流子片と電機子コイル導体の接続状態を示す斜視図である。
【図３】この発明の実施の形態２の回転電機用整流子装置を用いた回転体の断面図である。
【図４】図３に用いる整流子片の斜視図である。
【図５】この発明の実施の形態３の回転電機用整流子装置を用いた回転体の断面図である。
【図６】図５の電機子コイル導体の口出部の斜視図である。
【符号の説明】
１ 電機子、２ 積層鉄心、３ 端板、４ シャフト、５ 電機子コイル導体、６、２６ 整流子、７、２２、３６ 整流子片、８、２７、３７ 整流子胴、９、２９ （整流子胴の）外周部、１０ （整流子胴の）外周面、１１、２３ 整流子面、１２ （整流子胴の）内周面、１３ （整流子胴の）底面、１４ 境界線、１５ 段差部、１６ 銅線、１７ 絶縁皮膜、１８、３２ （電機子コイル導体の）口出部、１９、３０、４０ 接続面、２０、３１、４１ （接続面の）辺、２１、３３ （口出部の）端面、２４ （突起部の）溶接部、２５ 突起部、２８、３８ 外周面端部、３４ 円柱部、３５ （口出部の）窪み、３９ 境界。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a commutator device for a rotating electric machine used for a DC motor, and more particularly to a commutator device for a rotating electric machine in which a commutator piece and an armature coil conductor are connected by ultrasonic welding.
[0002]
[Prior art]
In the present invention, the commutator device for a rotating electric machine means a commutator to which a lead portion of an armature coil conductor of the rotating electric machine is connected.
[0003]
In a conventional commutator device for a rotating electric machine, a commutator piece and an armature coil conductor are connected using an ultrasonic welding method, and the rotor is fixed by press-fitting the armature and the commutator coaxially to a shaft. ing. The armature has a laminated core having a plurality of slots in the circumferential direction near the outer edge, an end plate having a slot at the same position as the laminated core, a shaft having the laminated core and the end plate press-fitted and fixed, a laminated core and And a U-shaped armature coil conductor that penetrates the slot of the end plate.
[0004]
The commutator includes a plurality of saddle-shaped commutator pieces arranged in a cylindrical shape and a cylindrical commutator body having the commutator pieces fixed as inserts, and the commutator body is press-fitted and fixed to a shaft. In order to absorb the variation in the longitudinal dimension of the saddle-shaped commutator piece, the axial dimension of the commutator body is longer in the longitudinal direction of the commutator piece, and the upper and lower ends of the commutator body are The resin protrudes outward from the commutator surface of the commutator piece.
[0005]
The armature coil conductor is formed by covering a copper wire having a round cross section with an insulating film, and is formed into a U-shape so as to be inserted into a slit of the armature. From the armature coil conductor drawn out from the armature coil to the commutator in the pull-out direction, only the insulating film is removed by cutting or the like from the both ends of the armature coil conductor. The lead portion is welded to the end of the commutator piece while holding down with an ultrasonic horn using an ultrasonic welding machine (for example, see Patent Document 1).
[0006]
[Patent Document 1]
JP-A-11-299154 (paragraph 0005, FIG. 11)
[0007]
[Problems to be solved by the invention]
However, the commutator device for a rotating electric machine as described above has the following problems.
Since the commutator piece is formed integrally with the commutator body by insert molding using an insert, the commutator face of the commutator piece is slightly recessed from the end of the commutator body. In addition, when the clearance between the insert mold and the commutator piece is slightly increased, resin burrs may protrude on the outer surface of the commutator piece. When the lead portion is ultrasonically welded to such a commutator piece, a part of the conductor hits the protruding resin, and the connection area of the connection surface between the commutator piece and the lead portion is reduced. Further, if resin burrs are interposed on the connection surface, the strength may be extremely reduced.
[0008]
In addition, in order to weld a round cross-section lead-out portion drawn from the armature coil to the commutator, which is a pull-out direction of the armature coil conductor, to a flat commutator piece, a connection located forward with respect to the pull-out direction. The front edge portion of the surface is bordered by the end face of the outlet, while the rear edge portion located rearward in the drawing direction has a pointed shape. When the armature coil conductor is energized to such a connection surface, the armature coil conductor generates heat, the stress caused by the thermal expansion of the armature coil conductor, the armature rotates, and the end plate of the armature coil conductor Stress due to the weight between the trailing edges of the connection surface is applied to the connection surface. In particular, when the stress is concentrated on the sharp trailing edge portion, there is a possibility that the joining strength of the connection surface is reduced by mechanical fatigue.
[0009]
It is an object of the present invention to provide a commutator device for a rotating electric machine that prevents concentration of a force when a force is applied to a connection surface between an armature coil conductor and a commutator piece.
[0010]
[Means for Solving the Problems]
In the commutator device for a rotating electric machine according to the present invention, an electric insulating commutator body attached to an armature rotating shaft, a plurality of commutator pieces supported by the commutator body, and a drawing direction from the armature coil. A commutator piece connected to the commutator piece, the commutator piece having a trailing edge portion in which a connection surface between the lead portion and the commutator piece is located rearward with respect to the drawing direction. In the slave device, the trailing edge portion of the connection surface is a straight line extending substantially perpendicular to the pull-out direction, and the force applied to the spout to separate from the connection is dispersed along the trailing edge portion. Let it.
[0011]
Further, the commutator device for a rotating electrical machine has a plurality of commutator pieces having a commutator surface, a stepless outer peripheral surface on the commutator surface, and a cylindrical shape in which the commutator pieces are embedded in an outer peripheral portion. In a commutator device for a rotating electric machine, comprising: a commutator body and an armature coil conductor having a lead portion connected to the commutator piece, a connection surface between the commutator piece and the lead portion. Has an outer edge that includes a side that is separated from the end surface of the outlet portion and that is parallel to the end surface.
[0012]
BEST MODE FOR CARRYING OUT THE INVENTION
Embodiment 1 FIG.
FIG. 1 is a sectional view of a rotor using a commutator device for a rotating electric machine according to a first embodiment of the present invention. FIG. 2 is a plan view showing a connection state between a commutator piece and a conductor in FIG.
The armature 1 has a laminated core 2 having a plurality of slots in the circumferential direction near the outer edge, an end plate 3 having a slot at the same position as the laminated core 2, and the laminated core 2 and the end plate 3 being press-fitted and fixed. It comprises a shaft 4 and an armature coil conductor 5 penetrating through the slots of the laminated core 2 and the end plate 3 and formed in a U-shape.
[0013]
The commutator 6 includes a plurality of saddle-shaped commutator pieces 7 made of copper and arranged in a cylindrical shape, and a cylindrical commutator body 8 to which the commutator pieces 7 are fixed as inserts. The commutator 6 is press-fitted and fixed to the shaft 4 and has a cylindrical shape as a whole. The outer peripheral portion 9 of the commutator cylinder 8 includes a portion covered with the commutator piece 7 and an outer peripheral surface 10 on which the resin of the commutator cylinder 8 is exposed.
[0014]
The commutator 6 is also manufactured by an insert molding method, and the insert uses a cylindrical member in which a plurality of commutator pieces 7 for one commutator 6 are connected at a part of a part. This cylindrical member is manufactured by processing a copper plate by a cold forging method. Protruding protrusions are provided on the inner peripheral surface of the cylindrical member to secure a coupling force between the commutator piece 7 and the commutator body 8. When this cylindrical member is set in an insert mold, molded with phenol resin, and then the outer periphery is cut, the connected portion is cut, and the commutator piece 7 is divided into individual pieces, and the commutator face is divided. A commutator 6 having a cylindrical shape in which the commutator pieces 7 in which 11 is arranged in a stepless manner with the outer peripheral surface 10 is embedded in the outer peripheral portion 9 is completed. A columnar hole 12 is provided around a cylindrical axis. The commutator 6 further cuts the outer peripheral surface 10 and the commutator surface 11 which are inserted into the shaft 4 and are in contact with the bottom surface 13 facing the armature 1 by about 0.5 mm from the commutator surface 11 bounded by the boundary 14 by cutting. A recessed ring-shaped circumferential step 15 is provided. The end positions of the commutator pieces 7 vary due to variations in the length of the commutator pieces 7 and positional deviations when setting the commutator pieces 7, so that a part of the end of the commutator pieces 7 is also included. An uneven portion 15 is provided.
[0015]
The armature coil conductor 5 is a U-shaped conductor formed by covering the outer periphery of a copper wire 16 having a round cross-sectional shape and having a diameter of about 2 mm and covered with an insulating film 17, from the armature 1 to the commutator 6. The both ends of the armature coil conductor 5 drawn out in the drawing direction are processed into a lead portion 18. The lead portion 18 has only the insulating film 17 removed by cutting or the like. Two lead portions 18 are vertically connected to one commutator piece 7 from the viewpoint of connection. The connection between the commutator piece 7 and the outlet portion 18 is performed by welding between the copper wire 16 and the commutator piece 7 by an ultrasonic welding method. The ultrasonic vibration is applied to the interface between the commutator piece 7 and the copper wires 16 and between the copper wires 16 while the outlet portion 18 is pressed by the ultrasonic horn, and welding is performed. Vibration is applied by aligning the ultrasonic horn with the position of the outlet 18 including the boundary 14. In this way, a connection surface 19 is formed between the lead portion 18 and the commutator piece 7, and the connection surface 19 is formed by the boundary line 14 at a position rearward in the drawing direction of the lead portion 18. A side 20 is provided as a trailing edge portion. The trailing edge portion, that is, the side 20 is a straight line extending in the circumferential direction. The side 20 was parallel to the end face 21 of the outlet 18 and the connection face 19 was rectangular.
[0016]
When the peel strength of the commutator piece 7 and the two copper wires 16 thus welded was measured, it was improved by about 10%, and the variation was reduced to about 60%. In particular, since the side 20 on the boundary line 14 is not a narrow connecting surface such as a long and narrow elliptical arc in the longitudinal direction, the peel strength of peeling the armature coil conductor 5 from the armature 1 side to the commutator 6 side is low. It is getting bigger.
[0017]
Further, when the connection point is observed after repeatedly driving the rotary electric motor using the commutator device for a rotary electric machine of the present invention, it can be seen that the conventional product has a crack at the tip of an elongated elliptical longitudinal arc. However, the first embodiment has improved.
[0018]
In the commutator device for a rotating electrical machine in which the commutator piece 7 and the armature coil conductor 5 are connected, the step 15 is provided at the end of the commutator piece 7, and the commutator face 11 and the step 15 As a result of welding including the boundary line 14, the shape of the welding surface 19 became rectangular and the peel strength increased.
[0019]
Furthermore, since the conductor 5 does not hit the outer peripheral surface 10a, the force applied to the conductor 5 from the ultrasonic horn does not escape, and uniform welding can be performed.
[0020]
Furthermore, when the step portion 15 is formed by cutting, burrs of the phenol resin crawling on the step portion 15 are removed at the same time. Become smaller.
[0021]
Embodiment 2 FIG.
FIG. 3 is a partial sectional view of a commutator device for a rotating electric machine according to Embodiment 2 of the present invention, and FIG. 4 is a perspective view of a contact piece used in FIG.
The difference from the first embodiment is that a rectangular projection 25 having a welded portion 24 protruding outward from the commutator surface 23 is provided at an end 22 a of the commutator piece 22.
[0022]
The commutator 26 can be manufactured in the same manner as in the first embodiment. The commutator 26 is also manufactured by an insert molding method, and the insert uses a cylindrical member in which a plurality of commutator pieces 22 of one commutator 26 are connected at a part of a portion. This cylindrical member is manufactured by processing a copper plate by a cold forging method. Protruding protrusions are provided on the inner peripheral surface of the cylindrical member to secure a coupling force between the commutator piece 22 and the commutator body 27. This cylindrical member is set in an insert mold, molded with phenol resin, and then the outer periphery is cut. The connected portion is cut, and the commutator piece 22 is divided into individual pieces, and the commutator face is cut. A commutator 26 having a cylindrical shape in which a commutator piece 22 in which 23 is arranged in a stepless manner with an outer peripheral surface 28 is embedded in an outer peripheral portion 29 is completed. At the time of this cutting, the amount of cutting in the radial direction is reduced by 0.3 mm to form the welded portion 24.
[0023]
The copper wire 16 from which the insulating film 17 of the lead portion 18 has been peeled off is welded to the protrusion 25 of the commutator piece 22 of the commutator 26 thus obtained by the ultrasonic welding method as in the first embodiment. The ultrasonic horn was welded in such a shape as to cover all the projections 25 of the commutator piece 22.
[0024]
The connection surface 30 between the commutator piece 22 and the copper wire 16 and the copper wire 16 connected by welding in this manner is substantially equal to the shape of the welded portion 24 of the projection 25 of the commutator piece 22 and is rectangular. The side 31, which is a rear edge portion of the surface 30 located rearward in the drawing direction of the outlet 18, was a line segment parallel to the end face 21 of the outlet 18.
[0025]
Also, the peel strength was measured at the initial stage and after the drive was performed by incorporating the same into the rotary motor, and the values were almost the same as those in the first embodiment.
[0026]
Such a commutator device for a rotating electric machine according to the second embodiment of the present invention has improved peel strength as in the first embodiment.
[0027]
Further, since the welded portion 24 of the projection 25 protrudes, the ultrasonic horn is adjusted and welded so as to hit the welded portion 24 of the projection 25 in parallel, so that the peel strength in the connection surface 30 becomes uniform.
[0028]
Embodiment 3 FIG.
FIG. 5 is a partial sectional view of a commutator device for a rotating electric machine according to Embodiment 3 of the present invention, and FIG. 6 is a perspective view of a lead portion of an armature coil conductor used in FIG.
A cylindrical portion 34 is provided over a desired length from the end face 33 of the lead portion 32 of the armature coil conductor 5. A depression 35 including a tangent side is formed in a circular cross section of the cylindrical portion 34 by processing with a die. This processing operation is performed simultaneously with the operation of peeling the insulating film 17 of the copper wire 16.
[0029]
The outlet 32 processed in this manner is connected to the commutator piece 36 by ultrasonic welding as in the first embodiment. At this time, the recess 35 of the outlet portion 32 is positioned so that the boundary line 39 between the cylindrical portion 34 and the recess 35 is positioned on the commutator piece 36 such that the recess 35 of the outlet portion 32 does not contact the outer peripheral end 38 of the commutator body 37. ing.
[0030]
A boundary line is formed on the outer edge, which is a rear edge portion located rearward with respect to the drawing direction of the outlet 32 of the commutator piece 36 and the copper wire 16 and the connection surface 40 between the copper wires 16 connected by welding in this manner. A side 41 on 39 was seen, and the side 41 was parallel to the end face 33 of the outlet 32.
[0031]
Therefore, the peel strength between the commutator piece 36 and the copper wire 16 was measured at the initial stage and after the assembly was driven in the rotary motor, and the values were almost the same as those in the first embodiment.
[0032]
Such a commutator device for a rotating electrical machine according to the third embodiment of the present invention has improved peel strength as in the first embodiment.
[0033]
Further, by performing the processing of the depressions simultaneously with the stripping work of the insulating film of the copper wire, a new man-hour is not required.
[0034]
Further, since the processing on the commutator cylinder side can be performed in the same manner as in the related art, it is not necessary to prepare a new injection mold.
[0035]
【The invention's effect】
As described above, the effects of the commutator device for a rotating electric machine according to the present invention are as follows.
(1) A commutator device for a rotating electric machine is drawn out in a drawing direction from an electric insulating commutator body attached to an armature rotating shaft, a plurality of commutator pieces supported by the commutator body, and an armature coil. A commutator device for a rotating electric machine, comprising: a lead portion connected to the commutator piece; and a connection surface between the lead portion and the commutator piece having a rear edge portion located rearward in the drawing direction. In the above, the rear edge portion of the connection surface is a straight line extending substantially at right angles to the drawing direction, so that the force to be peeled off from the connection applied to the outlet portion is dispersed along the rear edge portion. When the armature coil conductor is pulled from the armature side to the commutator side, and a stress is applied to the connection surface between the lead portion and the commutator piece, the stress is applied to the side perpendicular to the stress. Stress on the connection surface per unit length Risk of armature coil conductor is peeled off from the commutator segments is reduced.
[0036]
(2) A commutator device for a rotating electric machine is a cylindrical commutator having a plurality of commutator pieces having a commutator surface and a stepless outer peripheral surface on the commutator surface, the commutator pieces being embedded in the outer peripheral portion. In a commutator device for a rotating electrical machine, comprising a child body and an armature coil conductor having a lead portion connected to a commutator piece, at the outer edge of a mutual connection surface between the commutator piece and the lead portion, Since the side that is separated from the end face of the outlet and is parallel to the end face is included, the welding surface between the commutator piece and the armature coil conductor becomes rectangular, and the shape of the armature coil conductor and the shape of the commutator piece are reduced. The impact on welding strength etc. can be excluded.
[Brief description of the drawings]
FIG. 1 is a sectional view of a rotating body using a commutator device for a rotating electric machine according to Embodiment 1 of the present invention.
FIG. 2 is a perspective view showing a connection state between a commutator piece of FIG. 1 and an armature coil conductor.
FIG. 3 is a sectional view of a rotating body using a commutator device for a rotating electric machine according to Embodiment 2 of the present invention;
FIG. 4 is a perspective view of a commutator piece used in FIG. 3;
FIG. 5 is a sectional view of a rotating body using a commutator device for a rotating electric machine according to Embodiment 3 of the present invention;
FIG. 6 is a perspective view of a lead portion of the armature coil conductor of FIG. 5;
[Explanation of symbols]
1 armature, 2 laminated core, 3 end plates, 4 shafts, 5 armature coil conductors, 6, 26 commutator, 7, 22, 36 commutator pieces, 8, 27, 37 commutator body, 9, 29 (rectifier Outer peripheral part (of the commutator body), outer peripheral surface (of the commutator body), 11, 23 commutator surface, 12 inner circumferential surface (of the commutator body), 13 bottom surface (of the commutator body), 14 borderline, 15 steps Part, 16 copper wire, 17 insulation film, 18, 32 lead (of armature coil conductor), 19, 30, 40 connection surface, 20, 31, 41, (of connection surface) side, 21, 33 (lead Edge, 24 (projection) weld, 25 projection, 28, 38 perimeter edge, 34 cylinder, 35 depression (dip), 39 boundary.
