JP2007043834A - Method of manufacturing armature - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing an armature that can facilitate a process for arranging a conductor wire. <P>SOLUTION: The method comprises a "conductor wire arranging step" for arranging an end winding Ma that is part of a winding at a position corresponding to a connecting point 116a of a rectifier 108 in a step for constituting the winding M1 by using the conductor wire D; a "contacting step" that makes the connecting point 116a contact with the conductor wire D (conductor wire connecting part Mb of the end winding Ma) in the axial direction, by positioning an armature core in the axial direction, of the rectifier 108 after the conductor wire arranging step; and a "non-contact connecting step" that electrically connects the connecting point 116a and the conductor wire D, by laser welding (laser beam LB) after the contacting step. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an armature manufacturing method.

Conventionally, in a DC motor armature, a commutator and a conductive wire constituting a winding are electrically connected. And as a manufacturing method of such an armature, by winding a conducting wire around the connection part in the segment of a commutator, making a jig (for example, a pair of electrodes etc.) contact, and performing welding (contact welding) There is an electrical connection method. As another armature manufacturing method, there is a method in which a conducting wire is wound around a connecting portion in a commutator segment and the wires are electrically connected by laser welding (see, for example, Patent Document 1).
JP 2000-167679 A

  However, in the armature manufacturing method as described above, the process is complicated because the operation of winding the conductive wire, which is a separate operation from the process of forming the windings and the like with the conductive wire, is necessary. There is a problem of end. This causes a long manufacturing time.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide an armature manufacturing method capable of simplifying a process of arranging a conducting wire.

  In the first aspect of the present invention, the armature core having a plurality of radially extending tooth portions, the insulator attached to the armature core, and the teeth portion of the armature core to which the insulator is attached are wound. A conductive wire that continuously forms a wound winding and a plurality of connecting wires that connect the plurality of windings; a plurality of segments; and a connection portion that extends from the segment and is electrically connected to a part of the conductive wire. A method of manufacturing an armature including a commutator, wherein a conductor is disposed at a position corresponding to the connection portion in a process of configuring the winding or the connecting wire by the conductor, A method of manufacturing an armature, comprising a non-contact connection step of electrically connecting the connecting portion and the conductive wire by non-contact welding after the conductive wire arranging step.

  According to a second aspect of the present invention, in the armature manufacturing method according to the first aspect, the rectification is performed with respect to the armature core after the conductor arranging step and before the non-contact connection step. A contact step of bringing the connecting portion into contact with the conductive wire in the axial direction by positioning the child in the axial direction is provided.

  According to a third aspect of the present invention, in the armature manufacturing method according to the second aspect, in the contact step, the commutator is axially positioned with respect to the armature core, whereby the connection portion And the mounting portion formed on the insulator sandwich the conducting wire in the axial direction.

According to a fourth aspect of the present invention, in the armature manufacturing method according to any one of the first to third aspects, the insulator has a separating portion at a position corresponding to a base end portion of the teeth portion. In the conducting wire arranging step, when the conducting wire is wound to form the winding, a part of the windings are arranged radially inward from the separating portion, so that the diameter is larger than that of the separating portion. Separated from other windings arranged on the outer side in the direction and arranged at a position corresponding to the connecting portion, and in the non-contact connecting step, the connecting portion and the part of the windings are connected by non-contact welding. Connect electrically.
(Function)
According to the first aspect of the present invention, in the conductor arranging step, a part of the conductor is arranged at a position corresponding to the connecting portion in the process of forming the winding or the connecting wire by the conductor. That is, in the conductor arrangement process, the process of forming the winding or the connecting wire is not performed, and the operation of winding the conducting wire, which is a separate operation from the process of configuring the winding or the connecting line, is not performed, but simply a series of processes of configuring the winding or the connecting line. A part thereof is disposed at a position corresponding to the connection portion. Therefore, the manufacturing process can be simplified, and the manufacturing time can be shortened. In the non-contact connection process, since the connecting portion and the conductive wire are electrically connected by non-contact welding, the conductive wire is simply disposed at a position corresponding to the connecting portion as described above (for example, abutting so as to overlap). Only) is sufficient. In other words, when welding is performed by bringing a jig into contact with each other, it is necessary to secure a space for contacting the jig (for example, a pair of electrodes or the like) (for example, around a connecting portion by winding a conductive wire). However, in the case of non-contact welding, the space becomes unnecessary, and thus the connecting portion and the conductor can be easily electrically connected while performing the simple conductor arrangement process.

  According to the second aspect of the present invention, in the contact step after the conductor arranging step and before the non-contact connection step, the commutator is positioned in the axial direction with respect to the armature core. The part is in axial contact with the conductor. In this case, the commutator is not positioned in the axial direction with respect to the armature core in the conductor arranging step. Therefore, it is possible to avoid the commutator from interfering during the conductor arrangement process, and consequently increase the space factor of the winding, simplify the manufacturing process (conductor arrangement process), and shorten the manufacturing time. Can be achieved. Further, since the connecting portion is simultaneously brought into contact with the conductor in the axial direction in the originally essential process of positioning the commutator in the axial direction with respect to the armature core, the contact process does not increase the number of processes.

  According to the invention described in claim 3, in the contacting step, the commutator is positioned in the axial direction with respect to the armature core, so that the conducting wire is axially connected between the connecting portion and the mounting portion formed on the insulator. Sandwiched between. Therefore, it is prevented that the position of a conducting wire shifts in the non-contact connection process. As a result, the connecting portion and the conducting wire can be easily and satisfactorily electrically connected.

  According to the invention described in claim 4, the insulator has the separation portion at a position corresponding to the base end portion of the tooth portion, and the winding is formed by winding the conducting wire in the conducting wire arranging step. In this case, a part of the windings are arranged radially inward of the separating part, so that they are separated from other windings arranged radially outside of the separating part and at positions corresponding to the connecting parts. Be placed. And in a non-contact connection process, a connection part and some windings are electrically connected by non-contact welding. If it does in this way, it will prevent that other windings become obstructive at the time of the connection operation (non-contact connection process) of a connection part and some windings. In addition, since the part of the windings are wound and become difficult to move and are in a stable state, connection work (non-contact connection process) can be performed in the stable state. For these reasons, it is possible to easily perform the connection work (non-contact connection process) while preventing damage (short circuit) of the windings (other windings). In particular, by applying this method to the method according to claim 2 or 3, an effect that the contact process can be performed in a state where the conducting wire (part of the windings) is stable can be obtained. .

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the armature which can simplify the process of arrange | positioning conducting wire can be provided.

Hereinafter, an embodiment of the present invention will be described with reference to FIGS.
As shown in FIG. 1, the DC motor 101 of this embodiment includes a stator 102 and an armature (rotor) 103. The stator 102 includes a substantially cylindrical yoke housing 104 and a plurality (six in this embodiment) of magnets 105 arranged and fixed at equal angular intervals on the inner peripheral surface of the yoke housing 104. In the present embodiment, six magnets (six poles) are provided, and the number of magnetic poles is six.

  As shown in FIGS. 1 and 2, the armature 103 includes a rotating shaft 106, an armature core 107 fixed to the rotating shaft 106, and a commutator 108 that is also fixed to the rotating shaft 106. As shown in FIG. 2, the armature 103 can be rotated by a bearing G held on a housing including a yoke housing 104 (specifically, an end housing E that closes the yoke housing 104 and its opening) on both ends of the rotating shaft 106. It is supported by. In this state, the anode-side and cathode-side brushes 109a and 109b, which are held by the end housing E and perform power feeding, are pressed and slidably contacted with the outer periphery of the commutator 108. In this state, the armature core 107 is disposed so as to face the magnet 105 and be surrounded by the periphery.

  The armature core 107 has eight teeth T1 to T8 that extend radially about the rotation shaft 106, and slots S1 to S8 are formed between the teeth T1 to T8, respectively (FIG. 1). And FIG. 4 (a)).

  More specifically, as shown in FIG. 5, the armature core 107 has an annular fixed portion in which the rotation shaft 106 is fitted and a circumferential connection portion 107 a that connects the base ends of the teeth T <b> 1 to T <b> 8 in the circumferential direction. A portion 107b and a radial connecting portion 107c extending radially inward from a portion of the circumferential connecting portion 107a in the circumferential direction (every 90 °) and connecting the circumferential connecting portion 107a and the fixing portion 107b.

  An insulator X (see FIG. 5) is attached to one end side (upper side in FIG. 2) of the armature core 107 where the commutator 108 is disposed, and the axial direction is the side where the commutator 108 is not disposed. An insulator Y (see FIG. 6) is attached to the other end side (the lower side in FIG. 2).

  As shown in FIG. 5, the insulator X corresponds to the annular covering portion Xa covering the circumferential connecting portion 107a, the teeth covering portion Xb covering the teeth T1 to T8, and the base ends of the teeth T1 to T8. The separation portion Xc arranged in the above-described manner and a placement convex portion Xd as a placement portion disposed on the radially inner side of the separation portion Xc (that is, on the annular covering portion Xa) are provided. The insulator X is made of resin, and the respective parts (the annular covering part Xa, the teeth covering part Xb, the separating part Xc, and the mounting convex part Xd) are integrally formed. The annular covering portion Xa includes an axial covering portion Xe that covers the circumferential connecting portion 107a from the axial direction, and a radial covering portion that covers the outer peripheral surface (between adjacent teeth T1 to T8) of the circumferential connecting portion 107a from the radial direction. Xf. The radial covering portion Xf is formed in a rectangular shape when viewed from the axial direction so as to protrude outward in the radial direction toward the center between the teeth T1 to T8 adjacent in the circumferential direction, and is recessed radially inward at the corner. A groove Xg extending in the axial direction is formed. The angular angle is an angle corresponding to a regular octagon. The groove Xg is recessed in a substantially arc shape. Further, the separation part Xc protrudes in the axial direction from the tooth coating part Xb. The separation part Xc is formed so as to partition the teeth covering part Xb side and the placement convex part Xd side at the base end parts of the teeth T1 to T8. Further, the separation portion Xc is provided with a recess Xh extending from the radially inner side to the radially outer side. Moreover, the mounting convex part Xd protrudes in the axial direction from the teeth covering part Xb, and the protruding amount is set smaller than that of the separating part Xc. The mounting convex portion Xd of the present embodiment is formed in a substantially trapezoidal shape as viewed from the radial direction (a substantially trapezoidal shape in which the shorter of the two parallel sides is set at the tip (top surface)) ( (See FIG. 7).

  As shown in FIG. 6, the insulator Y corresponds to the annular covering portion Ya covering the circumferential connecting portion 107a, the teeth covering portion Yb covering the teeth T1 to T8, and the base end portions of the teeth T1 to T8. An outer wall Yc projecting in the axial direction intermittently in the circumferential direction and an inner wall Yd projecting in the axial direction in a substantially cylindrical shape inside the outer wall Yc (inner edge of the annular covering portion Ya) are provided. In the present embodiment, the outer wall Yc and the inner wall Yd constitute a guide part. The insulator Y is made of resin, and the respective parts (the annular covering part Ya, the teeth covering part Yb, the outer wall Yc, and the inner wall Yd) are integrally formed. The annular covering portion Ya includes an axial covering portion Ye that covers the circumferential connecting portion 107a from the axial direction, and a radial covering portion that covers the outer peripheral surface (between adjacent teeth T1 to T8) of the circumferential connecting portion 107a from the radial direction. Yf. The radial covering portion Yf is formed in a square shape when viewed from the axial direction so as to protrude outward in the radial direction toward the center between the teeth T1 to T8 adjacent in the circumferential direction, and is recessed radially inward at the corner. A groove Yg extending in the axial direction is formed. The angular angle is an angle corresponding to a regular octagon. Further, the groove Yg is recessed in a substantially arc shape.

  The armature 103 has windings M1 to M8 wound in concentrated winding on the teeth T1 to T8 of the armature core 107 to which the insulators X and Y are mounted (through the slots S1 to S8). And the conducting wire D which comprises continuously the connecting wire 110 (refer FIG.2, FIG.9 and FIG.10) which connects several coil | windings M1-M8 is provided. FIG. 4A is a schematic diagram in which the armature 103 is developed in a planar shape. The windings M1 to M8 are entirely disposed in the radial direction of the teeth T1 to T8 by being wound around the teeth T1 to T8 (with respect to the teeth T1 to T8). It is arranged so as to have a binding force. The crossover wire 110 is disposed across (over) at least one of the teeth T1 to T8 disposed in the circumferential direction so as to connect the two teeth (in the direction perpendicular to the axis). It is arranged to have tension.

  For example, the conductive wire D of the present embodiment first forms a winding M1 by being wound around the tooth T1 in a concentrated winding, and then forms a crossover 110 that reaches the tooth T6 across the teeth T8 and T7. Next, a pattern in which the winding M6 is formed by concentrated winding on the tooth T6 is repeatedly provided (see FIG. 10). FIG. 10 illustrates an intermediate stage in the process of arranging the conductive wire D as described above (a “conductor layout process” described later).

  Here, each of the windings M1 to M8 is the separation portion Xc except for the end winding Ma (see FIGS. 1 and 7) as a part of the winding that is the final winding (last winding). Is wound around the teeth T1 to T8 on the outer side in the radial direction, and movement toward the inner side in the radial direction is restricted by the separation portion Xc. Further, the conducting wire connecting portion Mb which is a part of the end winding Ma is disposed on the mounting convex portion Xd. That is, each of the windings M1 to M8 is separated into an end winding Ma (partial windings) and other windings by the separation part Xc.

  Moreover, each crossover 110 is arranged avoiding the above-mentioned placement convex part Xd. In this embodiment, as shown in FIGS. 2, 9, and 10, each crossover wire 110 is disposed on the other end side in the axial direction of the armature core 107 (opposite side where the commutator 108 is disposed). Is done. Each connecting wire 110 is guided along the circumferential direction radially inward of the teeth T1 to T8 by the guide portions (the outer wall Yc and the inner wall Yd). Specifically, each of the crossover wires 110 is restricted from moving radially outward by the outer wall Yc, and restricted radially inward by the inner wall Yd.

  Further, in the conductive wire D, the conductive wire connecting portion Mc (see FIG. 9) for connecting the conductive wire connecting portion Mb (one axial end side) and the connecting wire 110 (the other axial end side) is formed in the grooves Xg and Yg. Placed (substantially half accommodated).

  As shown in FIG. 2, the commutator 108 includes a commutator body 111 and a short-circuit member 112. The commutator body 111 includes a substantially cylindrical main body insulating material 113 and 24 segments 1 to 24 (see FIG. 4A) disposed on the outer peripheral surface of the main body insulating material 113 in the circumferential direction. The segments 1 to 24 are substantially cylindrical on the outer periphery of the main body insulating material 113, and the anode side and cathode side brushes 109a and 109b are brought into contact (pressing contact) from the outside in the radial direction.

  The short-circuit member 112 is fixed to the axial end of the commutator body 111 and electrically connects the 24 segments 1 to 24 at intervals of 120 degrees as shown in FIG. , 9, 17 and segments 5, 13, 21 are short-circuited (same potential). Specifically, as shown in FIG. 3, the short-circuit member 112 includes 24 short-circuit pieces 115 and 116 disposed in two layers sandwiching an insulating layer (insulating paper) 114, respectively. Each short-circuit piece 115 on one side (the layer on the front side in FIG. 3) has its radially inner end shifted by 60 ° in the circumferential direction (clockwise in FIG. 3) with respect to the radially outer end. It is formed as follows. In addition, each short-circuit piece 116 on the other side (in FIG. 3, a layer on the back side of the paper and indicated by a broken line) has a radially inner end portion that is circumferentially opposite to a radially outer end portion (in FIG. 3). , In a counterclockwise direction). The short-circuit pieces 115 and 116 of the two layers are electrically connected to each other between the radially inner ends and the radially outer ends (without the insulating layer 114 interposed). Thereby, the radial direction outer side edge part of the short circuit pieces 115 and 116 in the short circuit member 112 will be electrically connected to a 120 degree space | interval.

  And the short circuit member 112 is being fixed to the commutator main body 111 so that each radial direction outer side edge part may be electrically connected to the segments 1-24, respectively. In the present embodiment, the other end (the layer on the back side of the paper in FIG. 3 and indicated by a broken line) extends radially outward from the segments 1 to 24 at the radially outer end of the short-circuit piece 116. A connecting portion 116a (see FIG. 8) is formed. The connection portion 116a is electrically connected and fixed on the conductive wire connection portion Mb, which is a part of the end winding Ma, and the placement convex portion Xd. In the present embodiment, the conductor connecting portion Mb and the connecting portion 116a are stacked on the placement convex portion Xd in the axial direction, and more specifically, the connection portion 116a sandwiches the conductor connecting portion Mb together with the placement convex portion Xd. Placed in. The connecting portion 116a is disposed at a position corresponding to the concave portion Xh and the circumferential direction. Further, the connection portions 116a are formed at intervals of three (that is, eight in total) in the circumferential direction of the 24 short-circuit pieces 116.

Next, a manufacturing method of the armature 103 configured as described above will be described in detail. The manufacturing method of the armature 103 includes a “conductor arrangement process”, a “contact process”, and a “non-contact connection process”.
In the “conductor arrangement step”, a part of the windings M1 to M8 is formed by the conductor D (that is, during the winding operation) at a position corresponding to the connecting portion 116a (in this embodiment, mounted). (On the placement convex part Xd). Specifically, in the present embodiment, when each of the windings M1 to M8 is configured by the conductive wire D, the end winding Ma (as a partial winding which is the final winding (the last one winding) in each of the windings M1 to M8) 1 and FIG. 7) are arranged radially inward of the separation part Xc (so as to pass over the mounting convex part Xd), and other windings except for the end winding Ma are arranged in the radial direction of the separation part Xc. Place outside. In the present embodiment, the crossover wire 110 is disposed on the other end side in the axial direction of the armature core 107 (the side where the commutator 108 is not disposed) (see FIG. 10).

  Next, in the “contacting step”, the commutator 108 is axially positioned with respect to the armature core 107 to bring the connecting portion 116 a into contact with the conductor D in the axial direction. Specifically, in the present embodiment, the commutator 108 is fixed by press-fitting to the rotating shaft 106 to which the armature core 107 is fixed, thereby positioning in the axial direction, thereby connecting the connecting portion 116a to the end winding on the conductor D. The wire Ma is brought into contact with the conducting wire connecting portion Mb in the axial direction (see FIG. 8). Further, in this embodiment, at this time, the conductive wire D (conductive wire connecting portion Mb) is sandwiched in the axial direction between the connecting portion 116a and the placement convex portion Xd.

  Next, in the “non-contact connection process”, the connection portion 116a and the conductive wire D (conductive wire connection portion Mb) are electrically connected by non-contact welding. Specifically, in this embodiment, as shown in FIG. 8, the connection portion is electrically connected by laser welding that irradiates a laser beam LB. Moreover, in this Embodiment, a part of front-end | tip of the connection part 116a is melted and it electrically connects with the conducting wire D (conducting wire connection part Mb). In the present embodiment, the film of the conductor D (conductor connection portion Mb) is also melted at the same time in this “non-contact connection step”, but before the “contact step”, that is, before the connection portion 116a is contacted. You may make it melt | dissolve the film | membrane of the conducting wire D (conducting wire connection part Mb) by irradiating a laser beam.

  In the armature 103 configured as described above, the windings M1 to M8 constitute one closed loop in total. Note that the windings M1 to M8 of this embodiment form a closed loop in the order of M1, M4, M7, M2, M5, M8, M3, M6, M1,. That is, when the circuit formed by the windings M1 to M8 in FIG. 4A is developed in a visually easy-to-understand manner, it is as shown in FIG. 4B.

Next, characteristic effects of the above embodiment will be described below.
(1) In the “conductor arrangement step”, a part of the windings M1 to M8 is formed by the conductor D (that is, during the winding operation), and a part thereof is arranged at a position corresponding to the connection portion 116a. That is, in the “conductive wire arranging step”, an operation such as “winding the conductive wire around the connecting portion”, which is an operation far from the process of forming the windings M1 to M8 and the crossover wire 110 by the conductive wire D, is not performed, but simply the winding M1. In a series of processes constituting .about.M8, a part thereof (conductive wire connecting part Mb of the end winding Ma) is arranged at a position corresponding to the connecting part 116a. Therefore, the manufacturing process can be simplified as compared with the conventional technique of “winding the conductive wire around the connecting portion”, and the manufacturing time can be shortened. In the “non-contact connection process”, since the connection portion 116a and the conductive wire D are electrically connected by non-contact welding (laser welding), the conductive wire D (conductive wire connection portion Mb) is connected to the connection portion 116a as described above. The “conductor arrangement step” is sufficient when it is arranged at a position corresponding to (only contacted so as to overlap as in the present embodiment). In other words, when welding is performed by bringing a jig into contact with each other, it is necessary to secure a space for contacting the jig (for example, a pair of electrodes) (for example, by winding a conducting wire around the connecting portion). On the other hand, in the case of non-contact welding, the space becomes unnecessary, and therefore, the connection portion 116a is performed while performing the above-mentioned “conductor arrangement step” (simply contacting them so as to overlap each other as in the present embodiment). And the conductive wire D can be easily electrically connected.

  (2) In the “contact step” after the “conductor arrangement step” and before the “non-contact connection step”, the commutator 108 is positioned in the axial direction with respect to the armature core 107, thereby being connected. The portion 116a is brought into contact with the conducting wire D (the conducting wire connecting portion Mb) in the axial direction. In this case, the commutator 108 is not positioned in the axial direction with respect to the armature core 107 in the “conductor arrangement step”. Therefore, the commutator 108 can be prevented from interfering during the “conductor arrangement process”, and as a result, a higher space factor of the windings M1 to M8 and the manufacturing process (“conductor arrangement process”). Simplification and shortening of manufacturing time can be achieved. Further, since the connecting portion 116a is simultaneously contacted in the axial direction with the conductive wire D (conductive wire connecting portion Mb) in the originally essential process of positioning the commutator 108 in the axial direction with respect to the armature core 107, the “contact process” Does not increase the number of steps.

  (3) In the “contacting step”, the commutator 108 is positioned in the axial direction with respect to the armature core 107, so that the lead wire D (lead wire connecting portion Mb) is pivoted between the connecting portion 116a and the mounting convex portion Xd. Sandwiched in the direction. Therefore, it is prevented that the position of the conducting wire D (the conducting wire connecting portion Mb) is shifted during the subsequent “non-contact connecting step”. As a result, the connection part 116a and the conducting wire D (conducting wire connection part Mb) can be electrically connected easily and satisfactorily.

  (4) In the “conductive wire arranging step”, when the conductive wire D is wound to form the windings M1 to M8, an end winding as a part of the winding that is the final winding (last winding) Since Ma is arranged radially inward from the separation part Xc, it is separated from other windings arranged radially outside of the separation part Xc and is arranged at a position corresponding to the connection part 116a. . In the “non-contact connection process”, the connection portion 116a and the end winding Ma (conductive wire connection portion Mb) are electrically connected by non-contact welding. If it does in this way, it will be prevented that other windings become obstructive at the time of the connection operation ("non-contact connection process") of connecting part 116a and end winding Ma (conductor connection part Mb). Further, since the end winding Ma (conductive wire connecting portion Mb) is wound, it is difficult to move and is in a stable state, so that the connection work (“non-contact connection process”) can be performed in the stable state. For these reasons, it is possible to easily perform the connection operation (“non-contact connection process”) while preventing damage (short circuit) of the windings (other windings excluding the end winding Ma). Further, in the present embodiment, the “contact process” can be performed in a state where the conductive wire D (the end winding Ma (conductive wire connecting portion Mb)) is stable, and the connecting portion 116a can be easily and reliably connected to the conductive wire D. Can be contacted.

  (5) In the “conductor arrangement step”, the connecting wire 110 is arranged on the other end side in the axial direction of the armature core 107 (the side where the commutator 108 is not arranged), so the connecting portion 116a and the end winding Ma ( It is possible to prevent the crossover wire 110 from getting in the way during the connection work (“non-contact connection process”) with the conductor connection part Mb). Therefore, the connection work (“non-contact connection process”) can be easily performed while preventing damage to the crossover wire 110.

The above embodiment may be modified as follows.
In the above embodiment, the lead wire D (the lead wire connecting portion Mb) is sandwiched in the axial direction between the connecting portion 116a and the mounting convex portion Xd in the “contacting step”, but before the “non-contact connecting step”. If the connection part 116a and the conducting wire D are contacted, you may change into another method.

  For example, as shown in FIG. 11, the commutator 108 (connecting part 116b) is positioned in the axial direction with respect to the armature core 107 in advance before the “conductor arranging step”, and then the “conductor arranging step”. The conductive wire D may be disposed at a position corresponding to the connecting portion 116b (that is, the conductive wire connecting portion Mb is brought into contact with the connecting portion 116b). In this case, of course, the “contact process” in the above embodiment is not performed.

In the above embodiment, the non-contact welding in the “non-contact connection step” is laser welding, but may be changed to other non-contact welding such as arc welding or electron beam welding.
In the above embodiment, the mounting convex portion Xd on which the conductive wire connecting portion Mb and the connecting portion 116a are placed and electrically connected thereto protrudes in the axial direction from the teeth covering portion Xb, but is not limited thereto. Instead, it may be changed to a non-projecting placement part that is simply partitioned by the separation part Xc. In addition, the placement convex portion Xd is formed in a substantially trapezoidal shape when viewed from the radial direction, but of course, even if it is changed to a placement convex portion having another shape protruding in the axial direction from the teeth covering portion Xb. Good.

  In the above embodiment, the concave portion Xh extending radially outward is provided at a position corresponding to the connecting portion 116a in the separation portion Xc. However, the present invention is not limited to this, and the concave portion Xh is not formed. The separation unit may be changed. In other words, the separation part Xc may be changed to other shapes and configurations as long as a part of the windings (end winding Ma) and the other windings can be separated. The concave portion Xh makes it possible to easily irradiate the connection portion with the laser beam LB irradiated in the “non-contact connection step” to facilitate laser welding.

  In the above embodiment, the connecting wire 110 is arranged on the other end side in the axial direction of the armature core 107 (the side where the commutator 108 is not arranged) in the “conductive wire arranging step”. Instead, the crossover wire may be arranged on one end side in the axial direction of the armature core 107 (the side where the commutator 108 is arranged). Even in this case, it is desirable that the crossover wire 110 is disposed on the outer side in the radial direction from the separating portion Xc, for example, avoiding the placement convex portion Xd. Further, when the connecting wire is arranged on one end side in the axial direction of the armature core 107 (the side where the commutator 108 is arranged), the connecting portion of the commutator and the connecting wire may be electrically connected. Good. That is, in the “conductive wire arranging step”, a part of the connecting wire is arranged in the process corresponding to the connecting portion in the process of forming the connecting wire by the conductive wire, and in the subsequent “non-contact connecting step”, the connecting portion and a part of the connecting wire are arranged. May be electrically connected by non-contact welding (laser welding).

  In the “conductor arrangement step” of the above embodiment, when each of the windings M1 to M8 is configured by the conductor D, each winding is a final winding (the last one winding) as a part of the windings. The end winding Ma (see FIGS. 1 and 7) is arranged radially inward from the separation part Xc, but the last winding (last winding) is changed to the first winding (first winding). May be.

-The short circuit member 112 of the said embodiment may be changed into the thing of another structure, if predetermined segments can be electrically connected.
-In above-mentioned embodiment, although the connection part 116a of the commutator 108 was formed in the short circuit member 112 (the short circuit piece 116), if it is the structure extended from the segment of a commutator, it will not be limited to this. For example, a connecting portion integrally formed with the segment of the commutator body 111 may be used.

  In the above embodiment, the number of magnets 105 is 6, the number of slots S1 to S8 is 8, and the number of segments 1 to 24 is 24. However, the present invention is not limited to this. You may implement. For example, a DC motor with 8 magnets, 9 slots, and 36 segments, or a DC motor with 10 magnets, 12 slots, and 60 segments May be.

The technical idea that can be grasped from the above embodiments will be described below together with the effects thereof.
(A) In the armature manufacturing method according to claim 4, in the conductor arranging step, the connecting wire is arranged on a side of the armature core where the commutator is not arranged. Production method. If it does in this way, it will be prevented that a crossover becomes obstructive at the time of the connection operation (non-contact connection process) of a connection part and some windings. Therefore, it is possible to easily perform the connection work (non-contact connection process) while preventing damage to the crossover.

1 is a schematic configuration diagram of a motor in the present embodiment. FIG. 3 is a cross-sectional view of a main part of the motor in the present embodiment. The top view of the short circuit member in this Embodiment. (A) Explanatory drawing for demonstrating the armature of this Embodiment expand | deployed planarly. (B) The circuit diagram formed with the coil | winding of the armature of this Embodiment. The top view of the insulator and armature core of the axial direction one end side of this Embodiment. The bottom view of the insulator and armature core of the axial direction other end side of this Embodiment. The principal part expansion perspective view for demonstrating the armature in this Embodiment. The principal part expansion perspective view for demonstrating the manufacturing method of the armature in this Embodiment. The principal part expanded bottom view for demonstrating the armature in this Embodiment. The perspective view for demonstrating the armature in this Embodiment. The principal part expansion perspective view for demonstrating the manufacturing method of the armature in another example.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1-24 ... Segment, 107 ... Armature core, 108 ... Commutator, 110 ... Crossover, 116a, 116b ... Connection part, D ... Conductor, M1-M8 ... Winding, Ma ... End winding (some windings) Line), T1 to T8, teeth (tooth portion), X, insulator, Xc, separating portion, Xd, placing convex portion (mounting portion).

Claims (4)

An armature core having a plurality of teeth extending radially;
An insulator mounted on the armature core;
A conductive wire that continuously forms a winding wound around the teeth portion of the armature core to which the insulator is mounted and a crossover that connects the plurality of windings;
A method of manufacturing an armature comprising a plurality of segments and a commutator having a connection portion extending from the segments and electrically connected to a part of the conducting wire,
A conductor arrangement step of arranging a part of the winding or the connecting wire in a process corresponding to the connection portion in the process of configuring the winding or the crossover with the conductor;
A method of manufacturing an armature, comprising a non-contact connection step of electrically connecting the connecting portion and the conductive wire by non-contact welding after the conductive wire arranging step. In the manufacturing method of the armature of Claim 1,
By positioning the commutator in the axial direction with respect to the armature core after the conducting wire arranging step and before the non-contact connecting step, the connecting portion is brought into contact with the conducting wire in the axial direction. A method for manufacturing an armature, comprising: a contacting step. In the manufacturing method of the armature of Claim 2,
In the contacting step, the commutator is positioned in the axial direction with respect to the armature core, whereby the conductive wire is sandwiched in the axial direction between the connecting portion and the mounting portion formed in the insulator. A method for manufacturing an armature. In the manufacturing method of the armature according to any one of claims 1 to 3,
The insulator has a separating portion at a position corresponding to the base end portion of the teeth portion,
In the conducting wire arranging step, when the conducting wire is wound to form the winding, a part of the winding is arranged radially inward from the separating portion, thereby being arranged radially outside the separating portion. Separated from other windings and arranged at a position corresponding to the connection part,
In the non-contact connection process, the connection part and the part of the windings are electrically connected by non-contact welding.

Images