JP2011182508A - Armature of rotary electric machine, and manufacturing method for the armature - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an armature wherein it is possible to ensure a sufficient contact area at a welded point to obtain a stable weld strength even though a coil is slightly displaced due to any ultrasonic vibration and prevent a contact between coils adjoining each other in the circumferential direction. <P>SOLUTION: A lower coil lead-out part 3 and an upper coil lead-out part 4 are formed flat so that a commutator segment 2 and the lower coil lead-out part 3 and the lower coil lead-out part 3 and the upper coil lead-out part 4 are respectively brought into planar contact with each other and a predetermined contact area can be obtained. However, the circumferential width 4a of the upper coil lead-out part 4 is smaller than the circumferential width 3a of the lower coil lead-out part 3, and the circumferential width 3a of the lower coil lead-out part 3 is smaller than the circumferential width 2a of the commutator segment 2. In addition, the lower coil lead-out part 3 and the upper coil lead-out part 4 are formed flat so that a contact area between the commutator segment 2 and the lower coil lead-out part 3 and a contact area between the lower coil lead-out part 3 and the upper coil lead-out part 4 are substantially identical with each other. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to an armature for a rotating electrical machine having a commutator at one end of an armature shaft, and more particularly to a connection structure between a commutator and an armature coil and a method for manufacturing the armature.

Conventionally, a method of joining a lead portion of an armature coil to a commutator piece by ultrasonic welding is known (see Patent Documents 1 and 2).
Patent Document 1 describes a method of ultrasonic welding in which the circumferential dimension of the coil lead part is smaller than the radial dimension and the cross-sectional shape of the coil lead part is formed in an oval shape. According to this method, even when the coil diameter is increased in order to increase the cross-sectional area of the armature coil, the necessary coil cross-sectional area can be ensured without reducing the interval between the coil lead portions adjacent in the circumferential direction. it can.

  In Patent Document 2, in order to facilitate transmission of ultrasonic vibrations to a member to be welded, a lower coil lead portion and an upper coil lead portion are formed in a flat shape in advance, and the width dimension of both coil lead portions is set as a commutator. A technique is disclosed in which the contact area between the commutator piece and the lower coil lead-out portion and the contact area between the lower coil lead-out portion and the upper coil lead-out portion are increased by forming the width approximately the same as the width of the piece. .

JP-A-11-299154 JP-A-57-20147

  However, in the technique disclosed in Patent Document 1, since the radial dimension of both coil lead portions is increased, the outer diameter of the welded portion is necessarily increased. In this case, in order to ensure the centrifugal strength, a wider contact area is required, but with the structure of Patent Document 1, a wide contact area cannot be obtained. Moreover, since the cross-sectional shape of both coil lead-out parts is formed in an oval shape, the contact area between the lower coil lead-out part and the upper coil lead-out part becomes small, and there is a possibility that stable welding strength cannot be obtained.

  On the other hand, in the technique disclosed in Patent Document 2, the width dimensions of both coil lead portions are formed substantially the same as the width dimension of the commutator pieces. When a deviation in the circumferential direction occurs (especially when the lower coil lead portion and the upper coil lead portion are shifted in opposite directions), the contact area in the width direction decreases and the required welding strength cannot be obtained. There is a fear. Moreover, since the width dimension of both coil lead-out parts is formed substantially the same as the width dimension of the commutator piece, when both coil lead-out parts are shifted in the width direction, the other coil lead-out parts adjacent in the circumferential direction There is also a risk of contact.

Further, in Patent Documents 1 and 2, when the upper coil lead portion is shifted to the commutator side (the counter armature core side) in the axial direction with respect to the lower coil lead portion, the upper coil lead portion and the lower coil lead portion are Since the contacted axial length is shortened and a sufficient contact area cannot be obtained, there is a possibility that a necessary welding strength cannot be obtained. Also, when both coil lead portions are displaced in the axial direction, particularly when the lower coil lead portion and the upper coil lead portion are displaced in opposite directions, both coils come into strong contact with each other and the coating of both coils is damaged. There is a fear.
The present invention has been made based on the above circumstances, and its purpose is to ensure a sufficient contact area at a welded portion and a stable welding strength even if some coil displacement occurs due to ultrasonic vibration. An object of the present invention is to provide an armature for a rotating electrical machine that can be obtained and prevent contact between coils adjacent in the circumferential direction, and a method for manufacturing the armature.

(Invention of Claim 1)
The present invention has an armature core fixed to an armature shaft, a commutator provided at one end of the armature shaft, and an armature coil wound around the armature core. A mold resin fixed to the outer periphery of the armature shaft, and a plurality of commutator pieces held in the mold resin and arranged in a cylindrical shape in the circumferential direction of the armature shaft, and adjacent to each other in the circumferential direction. The matching commutator pieces are insulated from each other by a mold resin. The armature coil includes a lower layer coil disposed in the axial direction in a slot formed in the armature core and an outer side of the lower layer coil in the slot. An upper layer coil disposed in the direction of the armature core, one end of the lower coil taken out of the slot from one axial end surface of the armature core (referred to as a lower coil lead-out portion), and an upper layer coil The end of one end (referred to as the upper coil lead-out part) Is placed on the surface of the commutator piece, and the commutator piece and the lower coil lead portion, and the lower coil lead portion and the upper coil lead portion are joined by ultrasonic welding. The lower coil lead-out portion is formed in a flat shape so as to be in surface contact with the commutator piece, and the upper coil lead-out portion is formed in a flat shape so as to be in surface contact with the lower coil lead-out portion, and the commutator piece It is characterized in that the circumferential dimension of the lower coil lead portion is smaller than the circumferential dimension.

According to the above configuration, even if the lower coil lead portion is slightly displaced in the circumferential direction (width direction) with respect to the commutator piece due to ultrasonic vibration during welding, the deviation width of the lower coil lead portion is Within the range of the circumferential width, the contact area between the commutator piece and the lower coil lead portion does not decrease, and a sufficient contact area can be secured, so that stable welding strength can be obtained.
Further, since the circumferential dimension of the lower coil lead-out portion is smaller than the circumferential dimension of the commutator piece, even if the lower coil lead-out portion is slightly displaced in the circumferential direction with respect to the commutator piece, the commutator The lower coil lead-out portion does not protrude from the range of the circumferential width of the piece, and contact with other lower coil lead-out portions adjacent in the circumferential direction can be prevented.

(Invention of Claim 2)
The present invention has an armature core fixed to an armature shaft, a commutator provided at one end of the armature shaft, and an armature coil wound around the armature core. A mold resin fixed to the outer periphery of the armature shaft, and a plurality of commutator pieces held in the mold resin and arranged in a cylindrical shape in the circumferential direction of the armature shaft, and adjacent to each other in the circumferential direction. The matching commutator pieces are insulated from each other by a mold resin. The armature coil includes a lower layer coil disposed in the axial direction in a slot formed in the armature core and an outer side of the lower layer coil in the slot. An upper layer coil disposed in the direction of the armature core, one end of the lower coil taken out of the slot from one axial end surface of the armature core (referred to as a lower coil lead-out portion), and an upper layer coil The end of one end (referred to as the upper coil lead-out part) Is placed on the surface of the commutator piece, and the commutator piece and the lower coil lead portion, and the lower coil lead portion and the upper coil lead portion are joined by ultrasonic welding. The lower coil lead-out portion is formed in a flat shape so as to be in surface contact with the commutator piece, and the upper coil lead-out portion is formed in a flat shape so as to be in surface contact with the lower coil lead-out portion, and the lower coil lead-out portion The dimension in the circumferential direction of the upper coil lead portion is smaller than the dimension in the circumferential direction.

According to the above configuration, even if the upper coil lead portion is slightly deviated in the circumferential direction (width direction) with respect to the lower coil lead portion due to ultrasonic vibration during welding, the deviation width of the upper coil lead portion is lower than the lower coil lead portion. As long as it is within the range of the circumferential width of the part, the contact area between the lower coil lead part and the upper coil lead part does not decrease, and a sufficient contact area can be secured, so that stable welding strength can be obtained. It becomes.
In addition, since the circumferential dimension of the upper coil lead part is smaller than the circumferential dimension of the lower coil lead part, even if the upper coil lead part is slightly displaced in the circumferential direction with respect to the lower coil lead part, The upper coil lead portion does not protrude from the range of the circumferential width of the lower coil lead portion, and contact with other upper coil lead portions adjacent in the circumferential direction can be prevented.

(Invention of Claim 3)
The armature for a rotating electrical machine according to claim 1 is characterized in that the dimension in the circumferential direction of the upper coil lead portion is smaller than the dimension in the circumferential direction of the lower coil lead portion.
According to the above configuration, in addition to the effect described in the first aspect of the invention, even if the upper coil lead portion is slightly displaced in the circumferential direction (width direction) with respect to the lower coil lead portion due to ultrasonic vibration during welding. If the deviation width of the upper coil lead-out portion is within the range of the circumferential width of the lower coil lead-out portion, the contact area between the lower coil lead-out portion and the upper coil lead-out portion does not decrease, and a sufficient contact area is provided. Therefore, stable welding strength can be obtained.
In addition, since the circumferential dimension of the upper coil lead part is smaller than the circumferential dimension of the lower coil lead part, even if the upper coil lead part is slightly displaced in the circumferential direction with respect to the lower coil lead part, The upper coil lead portion does not protrude from the range of the circumferential width of the lower coil lead portion, and contact with other upper coil lead portions adjacent in the circumferential direction can be prevented.

(Invention of Claim 4)
The present invention has an armature core fixed to an armature shaft, a commutator provided at one end of the armature shaft, and an armature coil wound around the armature core. A mold resin fixed to the outer periphery of the armature shaft, and a plurality of commutator pieces held in the mold resin and arranged in a cylindrical shape in the circumferential direction of the armature shaft, and adjacent to each other in the circumferential direction. The matching commutator pieces are insulated from each other by a mold resin. The armature coil includes a lower layer coil disposed in the axial direction in a slot formed in the armature core and an outer side of the lower layer coil in the slot. An upper layer coil disposed in the direction of the armature core, one end of the lower coil taken out of the slot from one axial end surface of the armature core (referred to as a lower coil lead-out portion), and an upper layer coil The end of one end (referred to as the upper coil lead-out part) Is placed on the surface of the commutator piece, and the commutator piece and the lower coil lead portion, and the lower coil lead portion and the upper coil lead portion are joined by ultrasonic welding. The lower coil lead portion is formed in a flat shape so as to be in surface contact with the commutator piece, and the upper coil lead portion is formed in a flat shape so as to be in surface contact with the lower coil lead portion, and the upper coil lead portion. The length in the axial direction of the lower coil lead portion is longer than the length in the axial direction.

  According to the above configuration, even if the upper coil lead portion is slightly displaced in the axial direction with respect to the lower coil lead portion due to ultrasonic vibration during welding, the upper coil lead portion is displaced in the axis of the lower coil lead portion. Within the range of the length in the direction, the contact area between the lower coil lead portion and the upper coil lead portion does not decrease, and a sufficient contact area can be secured, so that stable welding strength can be obtained. .

(Invention of Claim 5)
5. The armature for a rotating electric machine according to claim 4, wherein the lower layer coil and the upper layer coil are arranged at one end side of the two coils (one axial direction of the armature core) except for the lower coil lead portion and the upper coil lead portion joined together. A gap is provided between a portion taken out from the end face to the outside of the slot).
According to the above configuration, since the ultrasonic welding is performed in a state where a gap is provided between one end side of the lower coil and one end side of the upper coil, the lower coil lead portion and the upper coil are caused by ultrasonic vibration during welding. Even if the coil lead-out portion is slightly displaced in the axial direction, the one end side of the lower layer coil and the one end side of the upper layer coil do not come into strong contact with each other, and damage to the coating of the lower layer coil and the upper layer coil can be prevented.

(Invention of Claim 6)
The armature of any one of the rotating electrical machines according to any one of claims 1 to 5, wherein the lower layer coil and the upper layer coil include a contact area between the commutator piece and the lower coil lead portion, and a lower coil lead portion and an upper coil lead portion. Both coil lead portions are formed in a flat shape so that the contact area is the same.
According to the above configuration, the contact area between the commutator piece and the lower coil lead-out portion and the contact area between the lower coil lead-out portion and the upper coil lead-out portion are the same. Thus, stable welding strength can be secured.

(Invention of Claim 7)
It is the manufacturing method of the armature according to any one of claims 1 to 6, wherein the commutator piece and the lower coil lead portion, and the welding step of joining the lower coil lead portion and the upper coil lead portion by ultrasonic welding. Before, a flattening step is performed in which the lower coil lead portion and the upper coil lead portion are pressed and brought into close contact with each other in a flat shape.
In the above manufacturing method, the lower coil lead portion and the upper coil lead portion are brought into close contact with each other in advance before the welding step, so that the contact surfaces of both coil lead portions are in uniform contact and the contact area is Increase. As a result, both coil lead portions can be prevented from shifting in the circumferential direction during welding, and contact with both coil lead portions adjacent in the circumferential direction can also be prevented.

(Invention of Claim 8)
The armature manufacturing method according to claim 7, wherein the flattening step is performed by pressing the inner diameter punch having a convex curved surface formed with the same curvature as the surface of the commutator piece and the outer peripheral surface of the upper coil lead-out portion. Using the outer diameter punch that is applied, the inner circumference of the lower coil lead portion is received by the inner diameter punch, and the outer coil punch portion and the upper coil lead portion are pressed by pressing with the outer diameter punch from the outer peripheral side of the upper coil lead portion. Are formed in a flat shape at the same time and are brought into close contact with each other.
In the present invention, by using the inner diameter punch and the outer diameter punch and simultaneously pressing the lower coil lead portion and the upper coil lead portion, both coil lead portions are in contact with the contact surfaces of both coil lead portions. Since it can form in flat shape, a contact area increases.
Further, since the inner diameter punch has a convex curved surface formed with the same curvature as the surface of the commutator piece, the degree of adhesion between the inner peripheral surface of the lower coil lead portion and the surface of the commutator piece is also improved.

(Invention of Claim 9)
It is the manufacturing method of the armature according to any one of claims 1 to 6, wherein the commutator piece and the lower coil lead portion, and the welding step of joining the lower coil lead portion and the upper coil lead portion by ultrasonic welding. Before, by placing the lower coil lead portion and the upper coil lead portion stacked on the surface of the commutator piece in advance and pressing from the outer peripheral side of the upper coil lead portion, the commutator piece and the lower coil lead portion, And the flattening process which makes a lower coil extraction part and an upper coil extraction part closely_contact | adhere to flat shape is implemented, It is characterized by the above-mentioned.
In the above manufacturing method, since the lower coil lead portion and the upper coil lead portion are adhered in a flat shape on the surface of the commutator piece in advance before the welding process, the contact between the commutator piece and the lower coil lead portion is made in advance. The surface and the contact surfaces of both coil lead-out portions are in uniform contact, and the contact area increases. As a result, both coil lead portions can be prevented from shifting in the circumferential direction during welding, and contact with both coil lead portions adjacent in the circumferential direction can also be prevented.

(Invention of Claim 10)
The armature manufacturing method according to claim 9, wherein the flattening step uses an outer diameter punch pressed against the outer peripheral surface of the upper coil lead portion, and rectifies the lower coil lead portion and the upper coil lead portion. In a state of being superimposed on the surface of the child piece, by pressing with an outer diameter punch from the outer peripheral side of the upper coil lead portion, the lower coil lead portion and the upper coil lead portion are simultaneously formed into a flat shape, and are brought into close contact with each other. In addition, the commutator piece and the lower coil lead portion are brought into surface contact.
In the present invention, by simultaneously pressing the lower coil lead portion and the upper coil lead portion superimposed on the surface of the commutator piece with an outer diameter punch, the contact surface between the commutator piece and the lower coil lead portion, and Since both coil lead portions can be formed in a flat shape in a state where the contact surfaces of both coil lead portions are in close contact with each other, the contact area of the welded portion is increased.

(Invention of Claim 11)
The method for manufacturing an armature according to any one of claims 7 to 10, wherein in the flattening step, when the lower coil lead portion and the upper coil lead portion are pressed to form a flat shape, the lower coil lead portion is formed. The pair of side guides that regulate the circumferential width of the upper coil lead portion and the circumferential width of the upper coil lead portion are used, and this pair of side guides is more than the lower coil guide portion that restricts the circumferential width of the lower coil lead portion. The upper coil guide part that regulates the circumferential width of the upper coil lead part is formed narrower.
If there is no side guide when performing the flattening process, when both coil lead portions are pressed, the lower coil lead portion and the upper coil lead portion receive the same applied pressure, so the circumferential width of both coil lead portions Are substantially the same dimensions. In this case, since the contact area between the commutator piece and the lower coil lead portion is not the same as the contact area of both coil lead portions, it is difficult to obtain stable welding strength.

On the other hand, in the present invention according to claim 11, the upper coil lead portion formed in a flat shape by regulating the circumferential width of both coil lead portions using a pair of side guides during the flattening step. Can be made smaller than the circumferential width of the lower coil lead-out portion.
In other words, the pair of side guides is formed so that the upper coil guide part that regulates the circumferential width of the upper coil lead part is narrower than the lower coil guide part that regulates the circumferential width of the lower coil lead part. When both the coil lead portions are pressed simultaneously, the circumferential width of the upper coil lead portion is first regulated by the upper coil guide portion, and then the circumferential width of the lower coil lead portion is regulated by the lower coil guide portion. Thereby, since the flatness degree of the upper coil lead-out part is weak and the flatness degree of the lower coil lead-out part becomes strong, the circumferential width of the lower coil lead-out part can be made larger than the circumferential width of the upper coil lead-out part. As a result, the contact area between the commutator piece and the lower coil lead portion and the contact area of both coil lead portions can be formed substantially the same.

It is radial direction sectional drawing of the junction part which concerns on this invention (Example 1). It is radial direction sectional drawing of the junction part which shows the usage example of a side guide (Example 1). It is radial direction sectional drawing of the junction part when not using a side guide. (Example 2) which is an axial sectional drawing of the junction part which concerns on this invention.

  The best mode for carrying out the present invention will be described in detail with reference to the following examples.

Example 1
The armature of the rotating electrical machine described in the first embodiment can be applied to an armature of a starter motor (commutator motor) for starting an engine, for example.
The armature includes an armature core that is serrated (or simply press-fit) to the armature shaft, a commutator provided at one end of the armature shaft, and an electric machine wound around the armature core. And a child coil.
The armature core has a slot penetrating in the axial direction, and a plurality of slots are formed at regular intervals in the circumferential direction of the armature core.

As shown in FIG. 1, the commutator is composed of a mold resin 1 fixed to the outer periphery of an armature shaft (not shown) by press fitting or the like, and a plurality of commutator pieces 2 held by the mold resin 1. Is done. The plurality of commutator pieces 2 are arranged in a cylindrical shape with a certain interval in the circumferential direction of the armature shaft, and the commutator pieces 2 adjacent in the circumferential direction are insulated by the mold resin 1. Yes.
The armature coil includes a lower layer coil that is inserted inside the slot in the radial direction and assembled into the armature core, and an upper layer coil that is inserted into the slot in the radial direction, that is, outside the lower layer coil and assembled into the armature core. The lower layer coil and the upper layer coil are used in the same number as the number of slots.

One end side of each of the lower layer coil and the upper layer coil is taken out of the slot from one end surface in the axial direction of the armature core, and the end portion on each end side is overlapped on the surface of the commutator piece 2. 2 and one end of the lower coil, and one end of the lower coil and one end of the upper coil are joined by ultrasonic welding (see FIG. 1).
Hereinafter, the end portion on one end side of the lower layer coil is referred to as a lower coil lead portion 3, and the end portion on one end side of the upper layer coil is referred to as an upper coil lead portion 4.

Next, the features of the joint according to the present invention will be described with reference to FIG.
The lower layer coil and the upper layer coil use, for example, a coated copper wire having a circular cross section, and the lower coil lead portion 3 and the upper coil lead portion 4 are formed on the surface of the commutator piece 2, respectively. Are formed in a flat shape in which the dimension in the circumferential direction (left-right direction in the figure) is larger than the dimension in the direction in which they are superimposed (up-down direction in the figure). That is, the commutator piece 2 and the lower coil lead portion 3 and the lower coil lead portion 3 and the upper coil lead portion 4 are flattened so as to be in surface contact and to obtain a predetermined contact area. .

However, as shown in FIG. 1, the circumferential dimension (referred to as circumferential width) 4 a of the upper coil lead portion 4 is smaller than the circumferential width 3 a of the lower coil lead portion 3, and the circumferential direction of the lower coil lead portion 3. The width 3 a is formed smaller than the circumferential width 2 a of the commutator piece 2.
Further, the lower coil lead portion 3 and the upper coil lead portion 4 have substantially the same contact area between the commutator piece 2 and the lower coil lead portion 3 and the contact area between the lower coil lead portion 3 and the upper coil lead portion 4. It is formed in a flat shape so as to be the same. That is, the circumferential contact width A between the commutator piece 2 and the lower coil lead portion 3 and the circumferential contact width B between the lower coil lead portion 3 and the upper coil lead portion 4 have substantially the same dimensions. .

Here, the flattening process of the present invention in which the lower coil lead portion 3 and the upper coil lead portion 4 are respectively formed in a flat shape will be described.
The flattening step may be a first method performed on the surface of the commutator piece 2 and a second method performed using an inner diameter punch (not shown).
The first method is a method in which both coil lead portions 3 and 4 are stacked on the surface of the commutator piece 2 and pressed by an outer diameter punch (not shown) from the outer peripheral side of the upper coil lead portion 4. . The outer diameter punch may have a flat pressing surface for pressing the upper coil lead-out portion 4, but as shown in FIG. 1, both shoulder portions in the circumferential direction of the flat upper coil lead-out portion 4 are smooth. It is desirable to provide concave curved surfaces having a predetermined curvature on both sides of the pressing surface corresponding to both shoulder portions of the upper coil lead portion 4 so as to have a curved shape.

  In the second method, flattening is not performed on the surface of the commutator piece 2, but the inner peripheral surface of the lower coil lead portion 3 is received by an inner diameter punch (not shown), and the outer peripheral side of the upper coil lead portion 4. This is a method of pressing with an outer diameter punch. In this case, the inner diameter punch has a convex curved surface formed with the same curvature as the surface of the commutator piece 2. In this second method, pressing with an outer diameter punch is the same as the first method, but when pressing with an outer diameter punch, both coil lead-out portions 3, 4 are formed on the surface of the commutator piece 2. There is no need to arrange them, and both the coil lead portions 3 and 4 can be simultaneously pressed and flattened by the inner diameter punch and the outer diameter punch, so that the commutator piece 2 and both coil lead portions 3 and 4 are aligned. There is no need.

Moreover, said flattening process can be performed using a pair of side surface guide 5 (refer FIG. 2) which regulates the circumferential direction width | variety 3a, 4a of both the coil lead-out parts 3 and 4. FIG.
As shown in FIG. 2, the pair of side surface guides 5 includes an upper coil guide portion that regulates the circumferential width 4 a of the upper coil lead portion 4 and a lower coil guide portion that regulates the circumferential width 3 a of the lower coil lead portion 3. The upper coil guide portion is narrower than the lower coil guide portion.
If the pair of side guides 5 are not provided when the flattening process is performed, when the coil lead portions 3 and 4 are pressed, the lower coil lead portion 3 and the upper coil lead portion 4 are simultaneously pressed with the same pressure. Therefore, for example, as shown in FIG. 3, the circumferential widths 3 a and 4 a of the coil lead-out portions 3 and 4 have substantially the same dimensions. In this case, the contact area between the commutator piece 2 and the lower coil lead-out portion 3 and the contact area between both the coil lead-out portions 3 and 4 are not the same. That is, as compared with the upper coil lead portion 4, the flatness of the lower coil lead portion 3 is weak (the flattening does not proceed), and the contact area between the commutator piece 2 and the lower coil lead portion 3 is insufficient. It is difficult to ensure a stable welding strength.

  On the other hand, when a pair of side surface guides 5 is used in the flattening step as in the present embodiment, the upper coil lead portion is more than the lower coil guide portion that regulates the circumferential width 3a of the lower coil lead portion 3. Since the upper coil guide portion that regulates the circumferential width 4a of the upper coil guide portion 4 is narrower, when both the coil lead portions 3 and 4 are pressed simultaneously, the circumferential width 4a of the upper coil lead portion 4 is the first. It is regulated by the upper coil guide part, and then the circumferential width 3a of the lower coil lead-out part 3 is regulated by the lower coil guide part. Accordingly, the flatness of the upper coil lead-out portion 4 is weak and the flatness of the lower coil lead-out portion 3 is strong. growing.

(Effect of Example 1)
In the joint between the commutator piece 2 and the coil lead portions 3 and 4 described in the first embodiment, the circumferential width 3 a of the lower coil lead portion 3 is larger than the circumferential width 4 a of the upper coil lead portion 4. In addition, the circumferential width 2a of the commutator piece 2 is formed larger than the circumferential width 3a of the lower coil lead-out portion 3. Thereby, a sufficient contact area can be ensured even when both coil lead-out portions 3 and 4 are slightly displaced in the circumferential direction due to ultrasonic vibration during welding. That is, when the lower coil lead-out portion 3 is displaced in the circumferential direction with respect to the commutator piece 2, if the deviation width is within the range of the circumferential width 2 a of the commutator piece 2, the commutator piece 2 and the lower coil lead-out are provided. The contact area with the part 3 does not decrease.
Similarly, when the upper coil lead portion 4 is displaced in the circumferential direction with respect to the lower coil lead portion 3, if the deviation width is within the range of the circumferential width 3 a of the lower coil lead portion 3, the lower coil lead portion 3. And the contact area between the upper coil lead-out portion 4 are not reduced.

Further, in both coil lead portions 3 and 4, the contact area between the commutator piece 2 and the lower coil lead portion 3 and the contact area between the lower coil lead portion 3 and the upper coil lead portion 4 are substantially the same. Has been flattened. In this case, the welding amount between the commutator piece 2 and the lower coil lead portion 3 and the weld location between the lower coil lead portion 3 and the upper coil lead portion 4 are substantially the same.
As described above, even when both coil lead portions 3 and 4 are slightly displaced in the circumferential direction due to ultrasonic vibration during welding, the gap between the commutator piece 2 and the lower coil lead portion 3 and the lower coil lead portion 3 and the upper coil lead-out portion 4 can each ensure a sufficient contact area, and the amount of penetration at each welding location is substantially the same, so that stable welding strength can be ensured.

Furthermore, the circumferential width 3a of the lower coil lead portion 3 is formed smaller than the circumferential width 2a of the commutator piece 2, and the circumferential width of the upper coil lead portion 4 is smaller than the circumferential width 3a of the lower coil lead portion 3. Since 4a is formed smaller, even if both coil lead-out portions 3 and 4 are slightly displaced in the circumferential direction with respect to the commutator piece 2, both coil lead-out portions 3 are within the range of the circumferential width of the commutator piece 2. 4 does not protrude, and contact with the other coil lead portions 3 and 4 adjacent in the circumferential direction can be prevented.
Moreover, in the flattening process which presses both the coil lead-out parts 3 and 4 flatly, by using a pair of side surface guide 5, the circumferential direction width | variety 3a, 4a of both coil lead-out parts 3 and 4 is made into a desired dimension. Since it can regulate, the above-mentioned circumferential dimension relationship (2a>3a> 4a) can be obtained reliably.
Further, by using the pair of side surface guides 5, the center in the width direction of both coil lead-out portions 3 and 4 can be made to coincide with the center in the width direction of the commutator piece 2. The circumferential displacement of the coil lead portions 3 and 4 with respect to the child piece 2 can be reliably prevented.

(Example 2)
In the second embodiment, as shown in FIG. 4, the length 3 b of the lower coil lead-out portion 3 in contact with the commutator piece 2 in the axial direction (horizontal direction in the drawing) is in contact with the lower coil lead-out portion 3. In the state where the coil lead portions 4 are longer than the axial length 4b of the coil lead portion 4 and the coil lead portions 3 and 4 are superimposed on the surface of the commutator piece 2 (before starting welding), the upper coil lead portion 4 is formed. The axial end surface of the lower coil lead-out portion 3 protrudes in the axial direction by a dimension L from the axial end surface (left end surface in the drawing). Further, as shown in FIG. 4, a gap S is provided between one end side 3A of the lower layer coil and the one end side 4A of the upper layer coil that are taken out from the slot from one axial end surface of the armature core. It is characterized by.
According to the above configuration, even if the upper coil lead portion 4 is slightly displaced in the axial direction with respect to the lower coil lead portion 3 due to ultrasonic vibration during welding, the upper coil lead portion 4 is not displaced. Within the range of the axial length 3b of the portion 3, the contact area between the lower coil lead portion 3 and the upper coil lead portion 4 does not decrease, and a stable welding strength can be obtained.

Further, by providing a gap S between one end side 3A of the lower coil and one end side 4A of the upper coil, the lower coil lead portion 3 and the upper coil lead portion 4 are axially moved by ultrasonic vibration during welding. Even if they are slightly deviated from each other, the one end side 3A of the lower layer coil and the one end side 4A of the upper layer coil do not come into strong contact, and damage to the coating of the lower layer coil and the upper layer coil can be prevented.
Further, by combining with the configuration described in the first embodiment, a sufficient contact area can be ensured even when both the coil lead-out portions 3 and 4 are slightly displaced in the circumferential direction, so that a more stable welding strength can be obtained. .

1 Mold resin 2 Commutator piece 2a Circumferential width of the commutator piece (dimension in the circumferential direction)
3 Lower coil lead-out part 3A One end side of lower coil 3a Circumferential width of lower coil lead-out part (dimension in the circumferential direction)
3b Axial length of lower coil lead portion 4 Upper coil lead portion 4A One end side of upper layer coil 4a Circumferential width of upper coil lead portion (circumferential dimension)
4b Axial length of upper coil lead-out part 5 A pair of side guides S A gap provided between one end side of the lower layer coil and one end side of the upper layer coil

Claims (11)

An armature core fixed to the armature shaft;
A commutator provided at one end of the armature shaft;
An armature coil wound around the armature core;
The commutator is composed of a mold resin fixed to the outer periphery of the armature shaft, and a plurality of commutator pieces held in the mold resin and arranged in a cylindrical shape in the circumferential direction of the armature shaft, And between the commutator pieces adjacent in the circumferential direction is insulated by the mold resin,
The armature coil includes a lower layer coil disposed in the axial direction through a slot formed in the armature core, and an upper layer coil disposed in the slot through the outer side of the lower layer coil in the axial direction. Have
An end portion on one end side of the lower layer coil (referred to as a lower coil lead portion) taken out from the one end surface in the axial direction of the armature core to the outside of the slot, and an end portion on the one end side of the upper layer coil (upper coil lead portion) And the commutator piece and the lower coil lead-out portion, and the lower coil lead-out portion and the upper coil lead-out portion are joined by ultrasonic welding. An armature of a rotating electric machine,
The lower coil lead portion is formed in a flat shape so as to be in surface contact with the commutator piece, and the upper coil lead portion is formed in a flat shape so as to be in surface contact with the lower coil lead portion, and An armature for a rotating electrical machine, wherein a dimension in a circumferential direction of the lower coil lead-out portion is smaller than a dimension in a circumferential direction of a commutator piece. An armature core fixed to the armature shaft;
A commutator provided at one end of the armature shaft;
An armature coil wound around the armature core;
The commutator is composed of a mold resin fixed to the outer periphery of the armature shaft, and a plurality of commutator pieces held in the mold resin and arranged in a cylindrical shape in the circumferential direction of the armature shaft, And between the commutator pieces adjacent in the circumferential direction is insulated by the mold resin,
The armature coil includes a lower layer coil disposed in the axial direction through a slot formed in the armature core, and an upper layer coil disposed in the slot through the outer side of the lower layer coil in the axial direction. Have
An end portion on one end side of the lower layer coil (referred to as a lower coil lead portion) taken out from the one end surface in the axial direction of the armature core to the outside of the slot, and an end portion on the one end side of the upper layer coil (upper coil lead portion) And the commutator piece and the lower coil lead-out portion, and the lower coil lead-out portion and the upper coil lead-out portion are joined by ultrasonic welding. An armature of a rotating electric machine,
The lower coil lead portion is formed in a flat shape so as to be in surface contact with the commutator piece, and the upper coil lead portion is formed in a flat shape so as to be in surface contact with the lower coil lead portion, and An armature for a rotating electrical machine, wherein a dimension in a circumferential direction of the upper coil lead portion is smaller than a dimension in a circumferential direction of a lower coil lead portion. In the armature of the rotating electric machine according to claim 1,
An armature for a rotating electrical machine, wherein a dimension in a circumferential direction of the upper coil lead portion is smaller than a dimension in a circumferential direction of the lower coil lead portion. An armature core fixed to the armature shaft;
A commutator provided at one end of the armature shaft;
An armature coil wound around the armature core;
The commutator is composed of a mold resin fixed to the outer periphery of the armature shaft, and a plurality of commutator pieces held in the mold resin and arranged in a cylindrical shape in the circumferential direction of the armature shaft, And between the commutator pieces adjacent in the circumferential direction is insulated by the mold resin,
The armature coil includes a lower layer coil disposed in the axial direction through a slot formed in the armature core, and an upper layer coil disposed in the slot through the outer side of the lower layer coil in the axial direction. Have
An end portion on one end side of the lower layer coil (referred to as a lower coil lead portion) taken out from the one end surface in the axial direction of the armature core to the outside of the slot, and an end portion on the one end side of the upper layer coil (upper coil lead portion) And the commutator piece and the lower coil lead-out portion, and the lower coil lead-out portion and the upper coil lead-out portion are joined by ultrasonic welding. An armature of a rotating electric machine,
The lower coil lead portion is formed in a flat shape so as to be in surface contact with the commutator piece, and the upper coil lead portion is formed in a flat shape so as to be in surface contact with the lower coil lead portion, and An armature for a rotating electrical machine, wherein the axial length of the lower coil lead portion is longer than the axial length of the upper coil lead portion. In the armature of the rotating electrical machine according to claim 4,
The lower layer coil and the upper layer coil are taken out from one end side of both coils (from one end surface in the axial direction of the armature core to the outside of the slot) excluding the lower coil lead portion and the upper coil lead portion joined to each other. An armature for a rotating electrical machine, characterized in that a gap is provided between them. In the armature of any one of the rotating electrical machines according to claims 1 to 5,
The lower coil and the upper coil are formed so that the contact area between the commutator piece and the lower coil lead portion is the same as the contact area between the lower coil lead portion and the upper coil lead portion. An armature for a rotating electric machine, characterized in that a lead-out portion is formed in a flat shape. A method of manufacturing an armature according to any one of claims 1 to 6,
Prior to the welding step of joining the commutator piece and the lower coil lead portion, and the lower coil lead portion and the upper coil lead portion by ultrasonic welding, the lower coil lead portion and the upper coil lead portion are previously provided. A method of manufacturing an armature, characterized in that a flattening step is performed in which the flattening process is performed so as to make a flat contact. A method of manufacturing an armature according to claim 7,
The flattening step uses an inner diameter punch having a convex curved surface formed with the same curvature as the surface of the commutator piece, and an outer diameter punch pressed against the outer peripheral surface of the upper coil lead portion,
By receiving the inner circumference of the lower coil lead portion with the inner diameter punch and pressing it with the outer diameter punch from the outer circumference side of the upper coil lead portion, the lower coil lead portion and the upper coil lead portion are simultaneously flattened. A method of manufacturing an armature, wherein the armature is formed in close contact with each other. A method of manufacturing an armature according to any one of claims 1 to 6,
Before the welding step of joining the commutator piece and the lower coil lead portion and the lower coil lead portion and the upper coil lead portion by ultrasonic welding, the lower coil is previously formed on the surface of the commutator piece. The lead portion and the upper coil lead portion are arranged in a stacked manner and pressed from the outer peripheral side of the upper coil lead portion, so that the commutator piece, the lower coil lead portion, and the lower coil lead portion and the top A method for manufacturing an armature, characterized in that a flattening step is performed in which the coil lead portions are in close contact with each other in a flat shape. A method of manufacturing an armature according to claim 9,
The flattening step uses an outer diameter punch pressed against the outer peripheral surface of the upper coil lead portion, and the lower coil lead portion and the upper coil lead portion are superposed on the surface of the commutator piece. The lower coil lead portion and the upper coil lead portion are simultaneously formed in flat shape by pressing from the outer peripheral side of the upper coil lead portion with the outer diameter punch, and the commutator piece And the lower coil lead portion in surface contact with each other. A method for manufacturing an armature according to any one of claims 7 to 10,
In the flattening step, when the lower coil lead portion and the upper coil lead portion are pressed and formed into a flat shape, a circumferential width of the lower coil lead portion and a circumferential width of the upper coil lead portion A pair of side guides that regulate the circumferential width of the upper coil lead portion than the lower coil guide portion that regulates the circumferential width of the lower coil lead portion. A method of manufacturing an armature, wherein the coil guide portion is formed narrower.

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