JP2006074906A - Commutator device and manufacturing method for commutator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a commutator device that is manufactured at low cost and has a long brush life. <P>SOLUTION: The flat commutator device is so constructed that brushes are abutted from the direction of rotation axis and rectifying portion pieces and a slip ring are provided on its brush sliding face. The commutator device is constructed of: the slip ring consisting of an outside slip ring 1 and an inside slip ring 2 that are concentrically and annularly placed on the brush sliding face; the rectifying portion pieces 3 and 4 formed of conductors that are divided by a predetermined angle in the area between both the slip rings 1 and 2 and are electrically connected with either the outside slip ring 1 or the inside slip ring 2; power feeding brushes 10 and 11 at (+) and (-) potentials that are slid on the slip rings 2 and 1 and feed power to them; and brushes 7, 8 and 9 that are slid on the rectifying portion pieces 3 and 4 and are electrically connected with lead terminals in respective phases. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a flat commutator device in which a brush comes into contact with a rotating shaft and includes a rectifying piece and a slip ring on a brush sliding surface, and a method of manufacturing the commutator.

  Conventionally, when assembling an annular rectifying piece and U-phase, V-phase, and W-phase slip rings having different diameters, after the slip ring is overlaid on each connecting side of the rectifying piece, the rectifying piece and There is one in which the overlapping portion of each connecting piece and each phase slip ring is welded from the back side of the slip ring (see, for example, paragraph [0005] of Patent Document 1).

  Further, a rectifier including an annular rectifying piece and a plurality of slip rings having different diameters which are formed separately from the rectifying piece and are concentrically arranged with respect to the rectifying piece and electrically connected thereto. A plurality of connecting piece portions that are integrally formed on the outer periphery of each slip ring and extending in the radial direction, and commutator pieces that are integrally formed concentrically with each slip ring across the tips of these connecting piece portions The rectifying piece and the commutator piece ring are formed in substantially the same shape, and the rectifying piece and the commutator piece ring are overlapped and integrally coupled, and the rectifying piece and each slip ring are the same. There existed what was comprised so that it might become planar shape (for example, refer claim 1, FIG. 4, FIG. 5 of patent document 1).

JP 2003-284291 A (paragraph [0005], claim 1, FIG. 4, FIG. 5)

  As described above, there has conventionally been a structure in which the rectifying piece and the slip ring are divided as separate members and arranged at predetermined positions and then joined by welding or the like. Further, in order to electrically connect the rectifying piece of each phase and the slip ring of the corresponding phase, a structure straddling a predetermined distance or more in a direction perpendicular to the brush sliding surface at a portion intersecting with the slip ring of the other phase was there.

  In the former structure, joining work such as welding is required at a plurality of locations, and in the latter structure, a member having a complicated shape having a U-shaped bent portion straddling the slip ring is required. As a result, in any case, there is a problem that the manufacturing cost becomes high.

  Further, since slip rings are required for the number of phases of the motor, there is a problem that the brush sliding surface of the rectifying piece is small and the brush life is short.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a commutator device that is inexpensive to manufacture and has a long brush life.

  The commutator device according to the present invention is a flat commutator device in which a brush abuts from the rotation axis direction and includes a rectifying piece and a slip ring on the brush sliding surface, and is arranged concentrically on the brush sliding surface. A slip ring composed of an outer slip ring and an inner slip ring, and an area sandwiched between the two slip rings and divided into a predetermined angle and electrically connected to either the outer slip ring or the inner slip ring. The rectifying piece made of a conductive conductor, the brush for feeding with the potential of (+) and (−) that feeds power by sliding to each slip ring, and the electrical lead to each phase lead terminal by sliding on each rectifying piece. It is comprised from the brush connected to.

  The commutator manufacturing method according to the present invention includes a slip ring composed of an outer slip ring and an inner slip ring arranged concentrically on the brush sliding surface, and a region sandwiched between the slip rings at predetermined angles. A commutator manufacturing method comprising a plurality of rectifying pieces made of a conductor that is divided and electrically connected to either the outer slip ring or the inner slip ring, the predetermined slip ring and the predetermined rectification The process of punching from the conductive plate in a state where the pieces are connected and in a state where the rectifying pieces are connected at the bridge portion, and the axial position of each brush sliding surface of the rectifying piece and the slip ring is the plate thickness of the conductive plate It is characterized by comprising a step of molding so as to deviate and a step of removing a bridge portion connecting the rectifying piece pieces.

  According to the commutator device of the present invention, any rectifying piece is disposed adjacent to the outer slip ring and the inner slip ring. Therefore, the electrical connection between the rectifying piece and the slip ring does not need to straddle the conductors of the other phases, and can have a simple shape that does not require the joining of the conductors as in the prior art. As a result, the manufacturing cost can be reduced. Conventionally, for example, a plurality of slip rings for U-phase, V-phase, and W-phase have been required. In the present invention, however, two slip rings for (−) feeding and (+) feeding are used. Therefore, the brush sliding surface of the rectifying piece that performs commutation can be greatly increased, and the brush life can be extended.

  According to the method of manufacturing a commutator according to the present invention, the commutator pieces can be handled as a single part from the punching process to the molding process in a state where the rectifying pieces are connected by a bridge. Further, since the bridge is separated from both slip rings in the axial direction by more than the plate thickness, the bridge can be removed without damaging both slip rings. Furthermore, since the relative positions of the members are determined in the punching step, the positioning accuracy between the members (two slip rings, each rectifying piece) can be improved to the same level as the punching accuracy.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

Embodiment 1 FIG.
1A is a front view of a commutator having a rectifying piece and a slip ring according to Embodiment 1 of the present invention, FIG. 1B is a cross-sectional view taken along the line AA in FIG. c) is a sectional view taken along line BB in FIG. 1A, FIG. 1D is a sectional view taken along line CC in FIG. 1A, and FIG. 1E is a DD line in FIG. It is line sectional drawing. FIG. 6 is a sectional view showing a DC motor to which the commutator device according to Embodiment 1 of the present invention is applied.

  In the present embodiment, a case of a three-phase (U phase, V phase, W phase) DC motor that flows eight revolutions while the rotor rotates 360 degrees in mechanical angle will be described as an example.

  In FIG. 6, a DC motor 13 is a motor for opening and closing an EGR valve, for example, and includes a rotor 14 on the inner diameter side and a stator 15 on the outer diameter side. A permanent magnet 16 is attached to the rotor 14 on a surface facing the stator 15, and an armature winding 17 is wound around the stator 15 via an insulating member 19. A commutator 18 is fixed to the axial end surface of the rotor 14 and rotates together with the rotor 14.

  As shown in FIGS. 1 and 6, the commutator 18 is arranged on the brush sliding surface in a concentric annular shape centered on the axis of the rotor 14 and the (−) potential slip ring 1 and (+ ) A potential slip ring 2 is provided. In an annular region sandwiched between these two slip rings 1 and 2, a fan-shaped (-) potential rectifying piece 3 connected to the (-) potential slip ring 1, and a (+) potential slip ring Fan-shaped (+) potential rectifying pieces 4 connected to 2 are alternately arranged at equal pitches in the circumferential direction. A (−) potential power supply brush 11 is in contact with the (−) potential slip ring 1, and a (+) potential power supply brush 10 is in contact with the (+) potential slip ring 2. Are in contact with the U-phase, V-phase, and W-phase brushes 7, 8, and 9, respectively. The materials of the slip rings 1 and 2 and the rectifying pieces 3 and 4 are conductors, and are made of, for example, a copper alloy slightly containing silver in consideration of sliding with a carbon brush.

  Further, an isolated member 5 that is not electrically connected to the slip rings 1 and 2 is disposed between the rectifying unit pieces 3 and 4. The axial position of the brush sliding surface of the isolated member 5 is substantially the same as the axial position of each rectifying piece 3, 4. In addition, the material of the isolated member 5 may be either a conductor or an insulator. However, the amount of wear due to the sliding of the brush is approximately equal to the amount of wear of the rectifying unit pieces 3 and 4 so that there is no step and smooth brush sliding. The same material as the rectifying pieces 3 and 4 is preferable because it is desirable for movement. Between the slip ring 1 and the rectifying piece 4, between the slip ring 2 and the rectifying piece 3, between the isolated member 5 and the rectifying pieces 3 and 4, and between the isolated member 5 and the slip rings 1 and 2. The gap is arranged with a necessary insulation distance. These gap portions and the outer periphery are filled with an insulating mold material 6, and the mold material 6 also serves to fix the relative positions of the members.

  FIG. 2 is a drawing drawn by removing the molding material 6 from FIG. 1A so that it can be seen how the slip rings 1 and 2 and the rectifying pieces 3 and 4 are connected at the portion hidden by the molding material 6. It is. The hatched portion indicates a conductor.

  FIG. 3 is a drawing in which a brush contact portion at a certain moment in FIG. 2 is added. U-phase brush contact portion 7a, V-phase brush contact portion 8a electrically connected to lead terminals (not shown) of the U-phase, V-phase, and W-phase of armature winding 17; The abutting portions 9a of the W-phase brush are on an annular region where the rectifying pieces 3 and 4 or the isolated piece 5 are present at a pitch of 120 degrees in electrical angle. The angle occupied by each of the rectifying pieces 3 and 4 in the annular region is about 30 degrees, and the angle occupied by each of the brush contact portions 7a, 8a and 9a of each phase is rectifying pieces 3 and 4 It is an angle slightly smaller than ½ of the angle occupied by each one. The reason for making it slightly smaller is to prevent a short circuit between the rectifying piece 3 and the rectifying piece 4. The contact portion 11 a of the (−) potential power supply brush is on the slip ring 1, and the contact portion 10 a of the (+) potential power supply brush is on the slip ring 2. The rotation direction positions of the contact portions 11a and 10a of the power supply brush may be arbitrary positions. The contact portions 7a, 8a, 9a, 11a, and 10a of the brush move in the circumferential direction along with the rotation of the rotor 14 while maintaining the relative positions thereof. The number of the rectifying unit pieces 3 and 4 is four, four each, and the number of the isolated members 5 is eight because of the number of commutations. When the number of commutations is 2N (N is a natural number), the number of rectifying pieces 3 and 4 is N, and the number of isolated members 5 is 2N.

  In the structure of the commutator device as described above, power is supplied to the two slip rings 1 and 2 by the power supply brushes 11 and 10, respectively, and the U, V, and W phase lead terminals of the armature winding 17 are electrically connected. The U-phase brush 7, V-phase brush 8, and W-phase brush 9 connected to each other are electrically connected to either the outer slip ring 1 or the inner slip ring 2 in the region between the two slip rings 1 and 2. The commutation is carried out by sliding the rectifying piece 3 and 4 connected to. FIG. 8 is a diagram illustrating commutation timing of the commutator device according to the present embodiment. In addition, FIG. 7 is a figure which shows the commutation timing of the conventional commutator apparatus.

  As described above, according to the configuration of the commutator device of the present embodiment, any of the rectifying unit pieces 3 and 4 is disposed adjacent to the slip rings 1 and 2. Therefore, the electrical connection conductor between the rectifying pieces 3 and 4 and the slip rings 1 and 2 does not need to straddle the conductors of the other phases, and can be formed into a simple shape that does not require the joining of the conductors. As a result, the manufacturing cost can be reduced.

  Conventionally, three slip rings for U-phase, V-phase, and W-phase are required. In the present embodiment, slip rings 1 and 2 for (−) feeding and (+) feeding are used. Therefore, the brush sliding surfaces of the rectifying unit pieces 3 and 4 that perform commutation can be increased and the brush life can be extended.

  Furthermore, in the region between the rectifying piece 3 electrically connected to the outer slip ring 1 and the rectifying piece 4 electrically connected to the inner slip ring 2, the two slip rings 1 and 2 are electrically connected. Since there are no isolated members, and the axial positions of the brush sliding surfaces of the respective rectifying unit pieces 3 and 4 and each isolated member 5 are substantially the same, It is possible to prevent malfunction such as that the brushes 7, 8, and 9 electrically connected to the phase lead terminal fall into the gap between the rectifying piece and cannot be rotated.

  Further, since the material of the isolated member 5 is the same as the material of the rectifying unit pieces 3 and 4, the amount of wear of the isolated member 5 due to the sliding of the brush is approximately equal to the amount of wear of the rectifying unit pieces 3 and 4. Therefore, smooth brush sliding can be realized without causing a step between the two.

  Next, a method for manufacturing the commutator device according to Embodiment 1 of the present invention will be described. 4 and 5 are plan views for explaining the method of manufacturing the commutator device according to Embodiment 1 of the present invention. FIG. 4 is a view showing a state after the conductive plate material is punched, and FIG. It is a figure which shows the shape of an electroconductive board | plate material.

  First, as shown in FIG. 4, a predetermined slip ring 1, 2 and a predetermined rectifying piece 3, 4 are connected from a single conductive plate material (consisting of a copper alloy or the like containing a slight amount of silver). In a state in which the rectifying pieces 3 and 4 are connected by the bridge 12, the punching is performed. Next, as shown in FIG. 5, the brush sliding surface in the annular region where the rectifying pieces 3 and 4 and the isolated member 5 are present is axially perpendicular to the brush sliding surface of the slip rings 1 and 2, that is, the brush sliding surface. Plastic molding is performed so that the sheet thickness shifts more than the plate thickness. Then, after filling the molding material 6 and fixing each constituent member, the bridge 12 is removed by slit processing.

  According to such a manufacturing method, it can handle as a single part from a punching process to a plastic forming process in the state which the rectification | straightening part pieces 3 and 4 were connected with the bridge | bridging 12. FIG. Further, since the bridge 12 is separated from the slip rings 1 and 2 in the axial direction by more than the plate thickness, the bridge 12 can be removed without damaging the slip rings 1 and 2. Furthermore, since the relative positions of the members are determined in the punching process, the positioning accuracy between the members (slip rings 1 and 2, rectifying portion pieces 3 and 4) can be improved to the same level as the punching accuracy.

  Further, the molding material 6 is made of a material that is more easily worn than the rectifying pieces 3 and 4, so that the rectifying pieces 3 and 4 are rectified even if they are worn by sparks generated when the brushes 7, 8, 9 are slid. Since the mold material 6 in the gap between the pieces has a larger amount of wear, it does not protrude from the brush sliding surface, and malfunction due to the brushes 7, 8, 9, 10, 11 being caught can be prevented.

  The present invention is applied to, for example, a commutator that is assembled to a power feeding unit of a DC motor used in an EGR valve and a method for manufacturing the commutator.

It is the front view and side surface sectional view which show the commutator apparatus by Embodiment 1 of this invention. It is the top view which removed and showed the mold material from the commutator apparatus by Embodiment 1 of this invention. It is the top view which added the brush contact part of a certain moment of the commutator apparatus of FIG. It is a top view for demonstrating the manufacturing method of the commutator apparatus by Embodiment 1 of this invention. It is a top view for demonstrating the manufacturing method of the commutator apparatus by Embodiment 1 of this invention. It is sectional drawing which shows the DC motor to which the commutator apparatus by Embodiment 1 of this invention is applied. It is a figure which shows the commutation timing of the conventional commutator apparatus. It is a figure which shows the commutation timing of the commutator apparatus by Embodiment 1 of this invention.

Explanation of symbols

1 (−) potential slip ring, 2 (+) potential slip ring,
3 (-) potential rectifying piece, 4 (+) potential rectifying piece, 5 isolated member,
6 Mold material, 7 U phase brush, 8 V phase brush, 9 W phase brush,
10 (+) potential feeding brush, 11 (−) potential feeding brush, 18 commutator.

Claims (6)

In the flat commutator device in which the brush abuts from the rotation axis direction and includes a rectifying piece and a slip ring on the brush sliding surface,
A slip ring comprising an outer slip ring and an inner slip ring arranged concentrically on the brush sliding surface, and an outer slip ring or an inner divided into a region sandwiched between the two slip rings at predetermined angles A rectifying piece made of a conductor electrically connected to one of the slip rings, a brush for feeding (+) and (-) potentials that slides and feeds power to each slip ring, and the rectifying piece A commutator device characterized by comprising brushes that are slid to each phase lead terminal and electrically connected to each phase lead terminal. In the region between the rectifying piece electrically connected to the outer slip ring and the rectifying piece electrically connected to the inner slip ring, an isolated member that is not electrically connected to both slip rings is disposed. The commutator device according to claim 1, wherein axial positions of the brush sliding surfaces of the rectifying piece and each isolated member are substantially the same. The commutator device according to claim 2, wherein the material of the isolated member is the same material as that of the rectifying unit piece. The commutator device according to any one of claims 1 to 3, wherein a gap between the rectifying unit pieces is filled with an insulating material that is more easily worn than the rectifying unit piece. A slip ring composed of an outer slip ring and an inner slip ring arranged concentrically on the brush sliding surface, and an outer slip ring or an inner slip ring divided into a region sandwiched between both slip rings at a predetermined angle. A commutator manufacturing method comprising a plurality of rectifying pieces made of a conductor electrically connected to any one of
A process of punching from the conductive plate material in a state where the predetermined slip ring and the predetermined rectification piece are connected, and in a state where the rectification pieces are connected at the bridge portion;
Forming the axial position of each brush sliding surface of the rectifying piece and the slip ring so as to deviate more than the plate thickness of the conductive plate material;
And a step of removing a bridge portion that connects the rectifying piece pieces together. 6. The method of manufacturing a commutator according to claim 5, further comprising a step of filling a gap between the rectifying pieces with an insulating material that is more easily worn than the rectifying pieces.

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