JP2004194396A - Method of manufacturing segment for flat commutator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily and economically manufacture a segment which can prevent the leakage of resin in the resin molding process of a flat commutator. <P>SOLUTION: A segment 3 for a flat commutator is made by forming, by drawing, a bar 15, which has the same form as a segment 3, and die-cutting this bar 15 in a direction Z rectangular to the direction of drawing X. The drawing direction of the bar 15 is made roughly the same as the brush sliding direction of the segment 3, and the drawn face is made to serve as the brush sliding face 4 of the segment 3. An anchor 14 serves as a slip stop for the segment 3, and is made in the bar 15 at drawing. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a commutator manufacturing method for a rotating electrical machine, and more particularly to a method for manufacturing a segment in a disk-type flat commutator.
[0002]
[Prior art]
In recent years, motors used for electric power steering, engine starters, fuel pumps, and the like have adopted flat type commutators (flat commissors) due to demands for downsizing of the devices. Unlike a general cylindrical commutator, this flat commutator has a disk-shaped brush sliding surface extending in the radial direction from the rotating shaft, and a metal member called a commutator metal is molded integrally with a synthetic resin. The After integral molding, the commutator metal is radially cut so as to be insulated from each other and separated in the circumferential direction to form a plurality of segments. The brush is in sliding contact with the brush sliding surface made of this commutator metal from the axial direction, and the armature current is switched.
[0003]
As a method for producing a commutator metal in such a flat type commutator, a method for forming a segment for each segment individually by cold forging or forming a chain in an annular shape by a progressive press is adopted. It has been. However, according to these methods, there is a problem that the curved surface (R) of the bending corner portion becomes large due to press bending, ironing, drawing, or the like. When the corner portion R is increased, the length of the brush sliding surface is reduced by the R portion, which is disadvantageous in securing the sliding surface length. Also, the corner R generates a component force in the direction of floating the segment with respect to the resin pressure during resin molding. Further, since the commutator metal is manufactured in a complicated multi-step process that requires a progressive press, the equipment cost increases, and the blank area increases to secure the feed pilot hole, and the yield decreases accordingly.
[0004]
FIG. 6 is an explanatory diagram showing the influence of the corner R during resin molding. As shown in FIG. 6, in the corner portion R, the resin supplied from the gate 51 tends to go around from the corner portion 53 of the commutator metal 52 toward the brush sliding surface 54. Then, the commutator metal 52 is deformed upward by the pressure, and the resin may leak to the inner diameter side of the brush sliding surface 54. When the resin leakage occurs, not only deburring on the brush sliding surface 54 is required, but also a step is generated between the segments by the amount of the burr, and further a cutting process is required to absorb it. For this reason, the man-hour in the process after resin molding increases, and there existed a problem of causing a cost increase. In particular, in the commutator metal of the press product, there is a possibility that the metal is deformed from the spring back, and a countermeasure against resin leakage has been demanded.
[0005]
On the other hand, an attempt has been made to solve the above problem by applying a segment manufacturing method used in a normal cylindrical commutator. FIG. 7 is a partially sectional side view showing the configuration of the cylindrical commutator, and FIG. In the cylindrical commutator 55, the segment 56 is formed by appropriately cutting a bar-like member called a data bar. The data bar 57 is a copper drawn material, and has a trapezoidal cross section as shown in FIG. The segment 56 is punched out in the form indicated by the broken line in the drawing so that the segment bar 57 is used in the cylindrical commutator 55 of FIG.
[0006]
Therefore, a flat commutator segment (commutator metal) manufactured from such a tater bar 57 does not have a rounded corner R like a press product, and there is no problem of springback. FIG. 9 is an explanatory view showing a state in which a segment of a flat commutator is manufactured from a tater bar. If the segment 58 is cut out from the data bar 57 as indicated by a broken line in FIG. 9, the end portion of the brush sliding surface 59 does not become R. Therefore, even if the segment 58 is resin-molded, the resin does not wrap around the brush sliding surface 59, and the number of post-processing steps can be reduced.
[0007]
[Patent Document 1] JP-A-2000-125517 [Patent Document 2] JP-A-7-15917
[Problems to be solved by the invention]
However, when the segment 58 is punched from the data bar 57 as shown in FIG. 9, the processed surface becomes the brush sliding surface 54. That is, the fracture surface becomes the brush sliding surface 54. For this reason, the surface roughness of the brush sliding surface 54 is increased, and further cutting is required after the punching. Therefore, although the number of steps after molding is reduced, the number of segment manufacturing steps increases, and effective cost reduction cannot be achieved. Further, when the segment 58 is formed, since the deleted portion of the data bar 57 is relatively large, the yield is poor and the manufacturing cost is disadvantageous. Furthermore, since the inner portion softer than the surface of the data bar 57 becomes the brush sliding surface 54, there is a problem that the surface hardness is lowered, and the improvement has been desired.
[0009]
An object of the present invention is to easily and inexpensively manufacture a segment capable of preventing resin leakage in a resin molding process of a flat commutator, and to reduce the number of manufacturing steps of the flat commutator.
[0010]
[Means for Solving the Problems]
The flat commutator segment manufacturing method of the present invention includes a holder part formed in a disc shape with a synthetic resin, and a plurality of segments arranged along the circumferential direction on one axial end surface of the holder part. A method of manufacturing the segment in the flat type commutator, the step of forming a base material having a cross-sectional portion similar to the cross-sectional shape of the segment by drawing, and cutting the base material and Forming a segment.
[0011]
In the present invention, since the segment is manufactured by cutting the base material having the same cross-sectional shape as the segment, for example, the segment can be molded only by one punching process on the base material, Many punching processes are not required. Therefore, there is no dimensional variation due to matching of each process or feeding error, and the segment can be molded with high dimensional accuracy. In addition, since the base material is processed only by punching and feed accuracy is not required, the segment manufacturing equipment can be handled by a general-purpose and inexpensive equipment, and the segment can be processed at low cost.
[0012]
In the method for manufacturing a flat commutator segment, the drawing direction of the base material may be substantially the same direction as the brush sliding direction in the segment. Thereby, the processing direction of the brush sliding surface substantially coincides with the brush sliding contact direction, and the drawing surface can be used as the brush sliding surface as it is without performing a cutting finish after the punching.
[0013]
In the method for manufacturing a flat commutator segment, the drawing surface of the base material may be a brush sliding surface of the segment. As a result, the portion where work hardening has occurred in the drawing process becomes the brush sliding surface, the hardness of the brush sliding surface can be improved, and the durability of the commutator can be improved.
[0014]
Furthermore, in the manufacturing method of the segment for a flat type commutator, an anchor portion that prevents the segment from coming off in the axial direction with respect to the holder portion may be formed on the base material by the drawing process. Thereby, after the drawing process, an anchor portion forming operation such as a taper process or a nail cutting process becomes unnecessary, and the number of processes can be reduced.
[0015]
On the other hand, in the method for manufacturing a segment for a flat type commutator, the segment may be formed by punching the base material in a direction perpendicular to the drawing direction. In this case, the segments may be punched in a state where the adjacent segments are inverted from each other on the inner diameter side and the outer diameter side. As a result, the unnecessary portion of the base material is reduced, the segment can be punched very efficiently, the yield of the segment can be improved, not only the manufacturing cost can be reduced, but also the waste can be reduced. .
[0016]
DETAILED DESCRIPTION OF THE INVENTION
(Embodiment 1)
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a partially cut perspective view showing an example of a flat commutator using segments manufactured by the manufacturing method according to the present invention.
[0017]
The commutator 1 has a flat structure as shown in FIG. 1, and is used for a starter motor, an in-tank fuel supply pump, and the like. The commutator 1 includes a holder portion 2 made of synthetic resin and a plurality of metal segments 3. The segment 3 is molded integrally with the holder portion 2. The surface of the segment 3 (upper surface in FIG. 1) is a brush sliding surface 4, and a brush (not shown) comes into contact therewith from the axial direction.
[0018]
Such a commutator 1 is formed by mounting the individual segments 3 on a circular cartridge and molding the whole with synthetic resin in this state. The molded commutator 1 is assembled together with a rotating shaft, an armature core, and a coil winding (not shown), and then coated with a synthetic resin to form an armature assembly.
[0019]
The holder portion 2 is formed in a thick, substantially disk shape, and a shaft hole 5 for fixing the motor rotation shaft is formed in the center portion. A plurality of segments 3 are arranged at equal intervals on one end surface in the axial direction of the holder portion 2. Each segment 3 is formed in a substantially fan shape, and is arranged radially on the surface of the holder portion 2. Between the segments 3, slits 6 for electrically insulating adjacent segments 3 from each other are formed.
[0020]
FIG. 2 is a perspective view showing the configuration of the segment 3. As shown in FIG. 2, the segment 3 has a main body portion 7 on which the brush sliding surface 4 is formed, and an outer peripheral portion 8 formed by providing a step on the outside of the main body portion 7. A U-shaped coil mounting groove 9 is provided on the outer peripheral portion 8. An armature coil (not shown) is fixed to the coil mounting groove 9 by fusing or the like.
[0021]
A boss portion 11 is provided on the inner peripheral side of the main body portion 7, and a tapered portion 12a is formed on the inner surface side thereof. The boundary between the main body portion 7 and the outer peripheral portion 8 is a stepped portion 13, and the inner surface side is also a tapered portion 12b. The taper portions 12a and 12b expand toward the main body portion 7 side, and form an anchor portion 14 that prevents the segment 3 from coming off from the holder portion 2 in the axial direction.
[0022]
Such a segment 3 is formed as follows. 3 and 4 are explanatory views showing a method of manufacturing the segment 3 according to the first embodiment of the present invention. As shown in FIG. 3, the segment 3 is also cut out from a copper tater bar (base material) 15. The data bar 15 is formed by drawing a copper material in the direction indicated by the arrow X, and its cross section is formed in the same shape as the AA cross section in FIG. 2 of the segment 3 as shown in FIGS. That is, the tater bar 15 has a form in which a main body forming portion 17 that becomes the main body portion 7, an outer peripheral forming portion 18 that becomes the outer peripheral portion 8, and a boss forming portion 21 that becomes the boss portion 11 are integrally molded.
[0023]
A step portion 23 is formed between the main body forming portion 17 and the outer periphery forming portion 18 of the data bar 15, and tapered surfaces 22 a and 22 b are formed on the inside thereof. Since the cross-sectional shape of the data bar 15 is determined by the drawing die, the degree of freedom of the cross-sectional shape is greater than that of bending, and the tapered surfaces 22a and 22b can be easily formed on the inside of the boss portion 11 and the inside of the step portion 23. . In the commutator metal 52 by press working, as shown in FIG. 6, a step of processing the boss portion 61 into a tapered shape and a claw cutting step of forming the engagement piece 62 are necessary to prevent the slipping. On the other hand, in the segment 3, the anchor shape is formed at the same time in the drawing process, so that taper processing, nail cutting processing and the like are not required, and man-hours are reduced.
[0024]
The segment 3 is punched side by side from the data bar 15 as shown in FIG. Punching is performed in a direction perpendicular to the drawing direction X (Y direction in FIG. 3). Segment molding from the data bar 15 can be performed by a single punching process. Compared to many punching processes, there is no dimensional variation due to matching of each process or feeding error, and the segment 3 can be molded with high dimensional accuracy. . The equipment used at that time is only a punching process and the feed accuracy is not required. Therefore, the general-purpose and inexpensive equipment can be used, and the segment 3 can be processed at a low cost.
[0025]
Further, as shown in FIG. 4, in the punching process of the segment 3, the deleted area can be suppressed as compared with the case of FIG. Therefore, the material is effectively used and the yield is improved. Further, when the segment 3 is molded, there is no bending process, and the corner radius R is minimized. For this reason, the resin does not wrap around the brush sliding surface 4 by the resin mold, and the number of post-processing steps can be reduced.
[0026]
On the other hand, in the segment 3, the brush sliding surface 4 becomes the outer surface 17 a of the main body forming portion 17. That is, the drawing surface is the brush sliding surface 4. The drawing surface has a higher surface roughness and flatness than a fractured surface by punching, and can be used as the brush sliding surface 4 as it is. In the conventional segment of FIGS. 8 and 9, the drawing surface is buried in the resin mold, and the fracture surface is the brush sliding surface 4, which is not utilized even though there is a good surface. In contrast, in the segment 3, the drawing surface is set to be the brush sliding surface 4, and the good surface is actively utilized. Therefore, if the segment 3 is used, it is not necessary to finish the brush sliding surface 4 after the resin molding, and the man-hours for manufacturing the commutator 1 can be reduced. Note that the outer surface 17a of the main body forming portion 17 has a high hardness due to work hardening by drawing, and the durability of the brush sliding surface 4 is also improved.
[0027]
In general, the drawing direction X of the tater bar is perpendicular to the brush sliding contact direction (rotating direction) Z as shown in FIGS. From the viewpoint of the orientation of the material on the surface of the brush sliding surface 4, it is preferable that the processing direction and the brush sliding contact direction coincide with each other. However, in the case of FIGS. 8 and 9, since the brush sliding surface of the segment is scheduled to be finished after punching, there is not much influence even if both directions are different. On the other hand, on the brush sliding surface 4 of the segment 3, the drawing direction (X direction in FIG. 3) of the data bar 15 is substantially the same as the brush sliding contact direction (Z direction in FIG. 2). In this embodiment, the tangential direction of the brush sliding direction Z on the circumferential center line of the segment 3 (A-A line in FIG. 2) coincides with the drawing direction X of the tater bar 15. Therefore, in segment 3, post-processing due to the difference between the processing direction and the brush sliding direction can be omitted, and the product obtained by punching the data bar 15 as it is is combined with the goodness of the drawing surface and the surface hardness. Can be
[0028]
(Embodiment 2)
FIG. 5 is an explanatory diagram showing a segment manufacturing method according to the second embodiment of the present invention. In addition, the same code | symbol is attached | subjected about the part similar to Embodiment 1, and the description is abbreviate | omitted.
[0029]
In the manufacturing method of the second embodiment, so-called zigzag is performed on the tater bar (base material) 25 as shown in FIG. 5 in order to further increase the yield of the segment 3. A portion having the same cross-sectional shape as that of the segment 3 is formed in the data bar 25 so as to penetrate the adjacent segment 3 in the opposite direction in the vertical direction, and has a vertically symmetrical form. That is, the tater bar 25 has a shape in which the outer periphery forming portions 18 of the tater bar 15 are all provided in both ends and the outer end portions 26 are formed in both ends, each having the same cross-sectional shape as the segment 3.
[0030]
Adjacent segments 3 are punched up and down, that is, in an inverted form of the inner diameter side and the outer diameter side. In the data bar 25, the outer end 26 which is the inner diameter side (tapered side) is punched at a midway position, and the boss portion 11 is formed. As is clear from the comparison between FIGS. 4 and 5, in the manufacturing method, the unnecessary portion of the data bar 25 is small, and the segment 3 is punched very efficiently. Therefore, the yield of the segment 3 can be improved, not only the manufacturing cost can be reduced, but also the waste can be reduced.
[0031]
It goes without saying that the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the invention.
For example, in the above-described commutator 1, it is possible to omit the cutting finish for cleaning the brush sliding surface 4, but the flatness and surface roughness are appropriately set by cutting according to the required finished product accuracy. Finishing may be performed. However, even in that case, it is possible to reduce the number of steps such as grinding as compared with the conventional case.
[0032]
【The invention's effect】
According to the method for manufacturing a segment for a flat type commutator of the present invention, a base material having a cross-sectional portion similar to the cross-sectional shape of the segment is formed by drawing, and the base material is cut to form a segment. Therefore, the segment can be formed by cutting the base material, and multi-step processing is not required. Therefore, there is no dimensional variation due to matching of each process or feeding error, and the segment can be molded with high dimensional accuracy. In addition, since the feed accuracy is not required for processing of the base material, the segment manufacturing equipment can be handled by general-purpose and inexpensive equipment, and the segment can be processed at low cost.
[0033]
In addition, by making the drawing direction of the base material approximately the same as the brush sliding direction of the segment, the processing direction of the brush sliding surface can be made substantially coincident with the brush sliding contact direction, and the cutting finish can be performed after punching. The drawing surface can be used as it is as a brush sliding surface without performing it.
[0034]
Furthermore, by making the drawing surface of the base material the brush sliding surface of the segment, the site where work hardening has occurred in the drawing processing becomes the brush sliding surface, and the hardness of the brush sliding surface can be improved. The durability of the commutator can be improved.
[0035]
In addition, by forming the anchor portion on the base material by drawing, there is no need for anchor portion forming work such as taper processing or nail cutting after the drawing step, and man-hours can be reduced.
[0036]
On the other hand, by punching from the base material in the state where the inner diameter side and the outer diameter side are reversed with respect to each other, unnecessary portions of the base material are reduced, the segment can be punched efficiently, and the yield of the segment is improved, Not only can the manufacturing cost be reduced, but also waste can be reduced.
[Brief description of the drawings]
FIG. 1 is a partially cut perspective view showing an example of a flat commutator using segments manufactured by a manufacturing method according to the present invention.
FIG. 2 is a perspective view showing a configuration of a segment of a flat commutator.
FIG. 3 is an explanatory diagram showing a segment manufacturing method according to the first embodiment of the present invention.
FIG. 4 is an explanatory diagram showing a segment manufacturing method according to the first embodiment of the present invention.
FIG. 5 is an explanatory diagram showing a segment manufacturing method according to the second embodiment of the present invention.
FIG. 6 is an explanatory diagram showing the influence of a corner R during resin molding.
FIG. 7 is a side view of a partial cross section showing the configuration of the cylindrical commutator.
FIG. 8 is an explanatory diagram of a method for manufacturing the segment used in FIG. 7;
FIG. 9 is an explanatory view showing a state in which a flat commutator segment is manufactured from a tater bar.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Commutator 2 Holder part 3 Segment 4 Brush sliding surface 5 Shaft hole 6 Slit 7 Main body part 8 Outer peripheral part 9 Coil mounting groove 11 Boss part 12a, 12b Taper part 13 Step part 14 Anchor part 15 Theta bar (base material)
17 Main body forming portion 17a Outer surface 18 Outer periphery forming portion 21 Boss forming portions 22a and 22b Tapered surface 23 Step portion 25 Data bar (base material)
26 Outer end 51 Gate 52 Commuter metal 53 Corner 54 Brush sliding surface 55 Cylindrical commutator 56 Segment 57 Data bar 58 Segment 59 Brush sliding surface 61 Boss part 62 Engagement piece X Data bar pulling direction Y Data bar punching direction Z Brush Sliding direction

Claims (6)

A method of manufacturing the segment in a flat commutator comprising a holder portion formed in a disc shape with a synthetic resin and a plurality of segments disposed along one circumferential surface on one axial end surface of the holder portion. There,
Forming a base material having a cross-sectional portion similar to the cross-sectional shape of the segment by drawing;
And a step of forming the segment by cutting the base material. 2. The method for manufacturing a flat commutator segment according to claim 1, wherein the drawing direction of the base material is substantially the same direction as the brush sliding direction in the segment. 3. The method for manufacturing a flat commutator segment according to claim 1, wherein a drawing surface of the base material is a brush sliding surface of the segment. The manufacturing method of the segment for flat type commutators according to any one of claims 1 to 3, wherein an anchor portion for preventing the segment from being axially removed from the holder portion is formed in the base material by the drawing process. A method for manufacturing a segment for a flat type commutator. The flat type commutator segment manufacturing method according to any one of claims 1 to 4, wherein the segment is formed by punching the base material in a direction perpendicular to a drawing direction thereof. Manufacturing method of segment for commutator. 6. The method of manufacturing a flat commutator segment according to claim 5, wherein the segment is punched in a state where the adjacent segments are inverted from each other on the inner diameter side and the outer diameter side. .

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