JP2015186345A - Rectifier, and manufacturing method of rectifier - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rectifier capable of suppressing enlargement in size and suppressing the number of electrical connection points.SOLUTION: A rectifier 13 includes: a rectifier main body 17 including a plurality of rectifier pieces 15 disposed in a circumferential direction and a main body insulator 16 disposed so as to hold the rectifier pieces 15 radially inside of the rectifier pieces 15; and a plurality of short-circuiting conductors 21 provided in an axial end of the rectifier main body 17 for electrically connecting the separated rectifier pieces 15 with each other. The short-circuiting conductor 21 is formed in a seamless manner, and its both ends 21a are electrically connected to the rectifier piece 15 inside of an outer peripheral surface of the rectifier piece 15.

Description

  The present invention relates to a commutator and a method for manufacturing the commutator.

  Conventionally, as a commutator provided in an armature (rotor) of a DC motor, a short-circuit wire (short-circuit conductor) is also locked to a connection claw that protrudes radially outward from the commutator piece and locks the winding. There is one in which predetermined commutator pieces separated by the short-circuit line are electrically connected to each other (for example, see Patent Document 1).

  Further, as a commutator, two short-circuit terminals (short-circuit plate material pieces) are electrically connected (welded or the like) to form a short-circuit conductor, and one end portion and the other end portion of the short-circuit conductor are respectively connected to the commutator piece. Some are electrically connected to the commutator piece on the inner side of the outer peripheral surface (see, for example, Patent Document 2).

JP 2000-134873 A JP 2006-325318 A

  However, in the commutator in which the shorting wire (short-circuit conductor) is also locked to the connection claw, the diameter of the commutator is ensured so as to secure a space around the connection claw so that adjacent commutator pieces in the circumferential direction are not short-circuited. It becomes necessary to increase the size of the direction.

  Moreover, in the case where two short-circuit terminals (short-circuit plate member pieces) are electrically connected (welded or the like) to form a short-circuit conductor, there is a problem that the number of electrical connection points (weld points) increases. This increases the number of work steps and causes an increase in cost.

  The present invention has been made in order to solve the above-described problems, and its purpose is to reduce the size of the commutator and to reduce the number of electrical connection points, And it is providing the manufacturing method of a commutator.

  A commutator that solves the above problems includes a commutator body having a plurality of commutator pieces arranged in the circumferential direction and a main body insulating material arranged to hold the commutator pieces radially inside the commutator pieces; A commutator provided with a plurality of short-circuit conductors provided at the axial end of the commutator body and electrically connecting the separated commutator pieces to each other, wherein the short-circuit conductor is formed seamlessly, Both end portions thereof are electrically connected to the commutator piece inside the outer peripheral surface of the commutator piece.

  According to this configuration, the short-circuit conductor is formed seamlessly, and both ends thereof are electrically connected to the commutator piece on the inner side of the outer peripheral surface of the commutator piece. The size can be prevented from increasing without using a wire, and the number of electrical connection points can be suppressed by a seamless short-circuit conductor.

In the commutator, it is preferable that a groove portion into which an end portion of the short-circuit conductor can be inserted is formed at an axial end portion of the commutator piece.
According to this configuration, since the groove portion into which the end portion of the short-circuit conductor can be inserted is formed at the axial end portion of the commutator piece, the short-circuit conductor can be easily positioned with respect to the commutator piece. Therefore, for example, a commutator can be easily manufactured by performing welding after positioning.

In the commutator, it is preferable that the plurality of short-circuit conductors have an intermediate portion embedded in an insulating material to maintain a distance therebetween.
According to this configuration, since the intermediate portions of the plurality of short-circuit conductors are embedded in the insulating material and the distance between them is maintained, the insulation state between the short-circuit conductors can be ensured and the handling is facilitated.

  In the commutator, a connection claw that is connected to at least one of the commutator piece and the short-circuit conductor by forming a connection claw portion that protrudes radially outward of the commutator piece and engages the winding. It is preferable to provide a member.

  According to the same configuration, the connection claw member that is formed on the radial claw of the commutator piece and is connected to at least one of the commutator piece and the short-circuit conductor is formed. In order to prepare, a connection nail | claw part can be provided only in the required location. Thereby, all the commutator pieces can be made into the same shape, for example, the waste at the time of manufacturing a commutator piece from a board | plate material can be eliminated. In other words, when the plate material for manufacturing a plurality of commutator pieces has a connection claw that is folded back from the commutator piece, a plate material having a length before being turned back is required, and a portion other than the portion where the connection claw is required Although the plate material is largely wasted, the waste can be eliminated.

  In the commutator, it is preferable that the connection claw member has an insertion hole through which an end portion of the short-circuit conductor is inserted at a base portion, and the base portion is sandwiched between the commutator piece and the insulating material.

  According to this configuration, the connection claw member has an insertion hole through which the end of the short-circuit conductor is inserted at the base, and the base is sandwiched between the commutator piece and the insulating material. And at least one of them can be electrically connected well and can be held firmly.

  A method of manufacturing a commutator that solves the above-described problem includes a commutator having a plurality of commutator pieces arranged in the circumferential direction and a main body insulating material arranged to hold the commutator pieces radially inside the commutator pieces. A commutator manufacturing method comprising: a main body; and a plurality of short-circuit conductors that are provided at axial ends of the commutator body and electrically connect the separated commutator pieces to each other. In a plate-like short-circuited conductor forming jig having a protrusion, a winding step of winding a conductor wire in a preset pattern sequentially in a jig groove between the protrusions, and the short circuit after the winding step A cutting step of cutting and removing the conductor wire on one side of the conductor forming jig to form the plurality of short-circuited conductors that are each seamless, and after the cutting step, both ends of the short-circuited conductor are connected to the commutator piece, respectively. Electrically connected to the commutator piece inside the outer peripheral surface of the And a connection step of.

  According to the method, in the winding step, the conductor wire is sequentially wound in a predetermined pattern in the jig groove between the protrusions in the short-circuit conductor forming jig, and in the cutting step, one side of the short-circuit conductor forming jig is wound. A plurality of short-circuit conductors each having no joint are formed by cutting and removing the conductor wire. In this way, it is possible to simultaneously form a plurality of short-circuit conductors each having no joint at a predetermined position. In the connecting step, both end portions of the short-circuit conductor are electrically connected to the commutator piece inside the outer peripheral surface of the commutator piece. Thus, the size of the short-circuit conductor can be prevented from increasing without using the space around the connection claw, and the number of electrical connection points can be suppressed by the seamless short-circuit conductor.

  In the manufacturing method of the commutator, the conductor wire material whose arrangement is held by the short-circuit conductor forming jig after the winding step and before the cutting step or after the cutting step or It is preferable to provide a short-circuit conductor burying step of covering a part of the short-circuit conductor with an insulating material.

  According to this method, in the short circuit conductor embedding step, a part of the conductor wire or the short circuit conductor whose arrangement is held by the short circuit conductor forming jig is covered with the insulating material. Therefore, it can be set as the state which kept the space | interval of a some short circuit conductor easily, while being able to ensure the insulation state of short circuit conductors, handling becomes easy.

  In the commutator and the commutator manufacturing method of the present invention, it is possible to suppress an increase in size and to suppress the number of electrical connection locations.

The partial cross section figure of the armature in one embodiment. The disassembled side view of the commutator in one Embodiment. The top view of the short circuit member by which the connection nail | claw member in one Embodiment is arrange | positioned. The schematic diagram for demonstrating the manufacturing method of the commutator in one Embodiment. The schematic diagram for demonstrating the manufacturing method of the commutator in one Embodiment. (A) is a top view of the short circuit member in one embodiment. (B) is a side view of the short circuit member in one embodiment.

Hereinafter, an embodiment of an armature (rotor) of a DC motor will be described with reference to FIGS.
As shown in FIG. 1, the armature 1 includes a rotary shaft 11 that is rotatably supported by a housing (not shown), an armature core 12 and a commutator 13 that are fixed to the rotary shaft 11, and an armature core 12. And a winding 14 to be wound. In addition, the armature core 12 of this embodiment is of 12 slots having 12 teeth.

  As shown in FIGS. 1 and 2, the commutator 13 includes a plurality of commutator pieces 15 arranged in the circumferential direction, and a main body insulating material arranged to hold the commutator pieces 15 on the radially inner side of the commutator pieces 15. 16 is provided with a commutator body 17. The commutator body 17 of the present embodiment has 24 commutator pieces 15. A groove 15a is formed at the axial end of one side of the commutator piece 15 (armature core 12 side). The groove portion 15a of the present embodiment is formed in the central portion in the circumferential direction of the commutator piece 15, and is formed in a slit shape so as to penetrate from the radially inner side (inner circumferential surface) to the radially outer side (outer circumferential surface). The power supply brush 18 held in a housing (not shown) is pressed against the outer peripheral surface of the commutator piece 15.

  The commutator 13 is fixed to an axial end portion on one side (armature core 12 side) of the commutator body 17, and a plurality of short-circuit conductors 21 that electrically connect predetermined commutator pieces 15 separated from each other. The short-circuit member 22 which has is provided. Specifically, 24 short-circuit conductors 21 of the present embodiment are provided in order to electrically connect eight adjacent commutator pieces 15 (every 120 °) in the circumferential direction. Each short-circuit conductor 21 is formed seamlessly (no welded portion or the like), and both end portions 21a thereof are electrically connected to the commutator piece 15 on the inner side of the outer peripheral surface of the commutator piece 15, respectively. In the present embodiment, both end portions 21a of the short-circuit conductor 21 are electrically connected to the commutator pieces 15 which are separated by being inserted into the groove portions 15a of the commutator pieces 15 and welded.

  As shown in FIGS. 2 and 3, the short-circuit member 22 includes a substantially disk-shaped insulating material 23 that holds an interval between the intermediate portions 21 b of the plurality of short-circuit conductors 21. That is, the short-circuit conductor 21 of the present embodiment includes both end portions 21a that protrude in the axial direction from one end surface of the insulating material 23 at positions 120 ° apart of the substantially disc-shaped insulating material 23, and the inside of the insulating material 23. The intermediate portions 21b of the plurality of short-circuit conductors 21 are arranged in the insulating material 23 so as to be insulated by their own insulating coatings while overlapping in the axial direction. . 1 and 2, only one intermediate portion 21b is shown.

  As shown in FIGS. 2, 3, and 6, recesses 23 a are formed at 45 ° intervals where the end 21 a of the short-circuit conductor 21 protrudes on one end face of the insulating material 23. As shown in FIGS. 2 and 3, a connection claw member 24 is disposed in the recess 23 a of the insulating material 23.

  Specifically, the connection claw member 24 of the present embodiment is made of a plated brass material. The connection claw member 24 protrudes radially outward of the commutator piece 15 and has a base 24b having an insertion hole 24a through which the end 21a of the short-circuit conductor 21 is inserted, and the winding 14 (see FIG. 1) is locked. Connecting claw portion 24c. The connection claw portion 24c is folded and welded to the outer peripheral surface side of the commutator piece 15 in a state where the winding 14 is entangled, but in FIG. 1, before the winding 14 is entangled. This state is illustrated. The connecting claw member 24 is first assembled with the base portion 24b fitted into the concave portion 23a and the end portion 21a of the short-circuit conductor 21 inserted into the insertion hole 24a. In this state, the short-circuit member 22 is attached to the commutator body 17. When assembled (the end portion 21 a is inserted into the groove portion 15 a), the base portion 24 b is sandwiched and held between the commutator piece 15 and the insulating material 23. Further, at the place where the connection claw portion 24c is provided, the welding electrode is pressed and contacted from the outside in the radial direction of the connection claw portion 24c and energized (resistance welding), whereby the connection claw portion 24c, the winding 14, and the rectification are performed. The child piece 15 and the end 21a of the short-circuit conductor 21 are electrically connected. Moreover, in the place where the connection claw part 24c is not provided, the welding electrode is pressed and contacted from the radially outer side of the commutator piece 15 and energized (resistance welding), whereby the commutator piece 15 and the short-circuit conductor are provided. The end 21a of 21 is electrically connected.

Next, a method for manufacturing the commutator 13 configured as described above will be described.
The manufacturing method of the commutator 13 of this embodiment includes a “winding step”, a “short-circuit conductor embedding step”, a “cutting step”, a “connection claw member disposing step”, and a “connecting step”.

  As shown in FIGS. 4 and 5, in the “winding step”, the repair between the protrusions 31 a in the plate-like short-circuit conductor forming jig 31 having a plurality of (in the present embodiment, 24) protrusions 31 a is provided. The conductor wire D is sequentially wound around the tool groove 31b in a preset pattern. The preset pattern is a pattern in which a conductor wire D serving as a short-circuit conductor 21 (specifically, an intermediate portion 21b) is disposed on one surface side of the short-circuit conductor forming jig 31, and in the present embodiment, This is a pattern that passes from the jig groove portion 31b separated by 120 ° on one surface side to the other surface side and passes from the jig groove portion 31b separated by 45 ° on the other surface side to the one surface side. In FIG. 4, the conductor wire D to be the short-circuit conductor 21 is sequentially wound on one surface (surface on the front side of the paper) from the beginning of winding in the “winding step”, and four portions to be the short-circuit conductor 21 are obtained. The state where the minute arrangement is performed is schematically shown. FIG. 5 schematically shows a state in which the “winding step” is completed and 24 portions to be short-circuited conductors 21 are arranged. In FIGS. 4 and 5, for convenience, the reference numerals are given to portions that will be short-circuited conductors 21 later (by being cut).

  Next, in the “short-circuit conductor embedding step”, a part of the conductor wire D (the portion to be the intermediate portion 21 b) whose arrangement is held by the short-circuit conductor forming jig 31 is covered with the insulating material 23. In other words, in this embodiment, the conductor wire D together with the short-circuit conductor forming jig 31 is placed in a mold (not shown) and filled with molten resin, and the insulating material 23 described above (see FIGS. 6A and 6B). Form.

  Next, in the “cutting step”, the conductor wire D on one side (the other side) of the short-circuiting conductor forming jig 31 (the portion indicated by the broken line on the back side in FIG. 5) is cut and removed, so that each joint is cut. A plurality of short-circuit conductors 21 having no gap are formed. At this time, the portion corresponding to the thickness of the short-circuit conductor forming jig 31 becomes the end portion 21 a of the short-circuit conductor 21.

Next, in the “connection claw member disposing step”, the connection claw member 24 is disposed in the recess 23 a formed in the insulating material 23.
Next, in the “connection step”, as described above, both end portions 21 a of the short-circuit conductor 21 are electrically connected to the commutator piece 15 on the inner side of the outer peripheral surface of the commutator piece 15. Specifically, both ends 21a of the short-circuit conductor 21 are electrically connected by being inserted into the groove 15a of the commutator piece 15 and welded.

Next, the operation of the armature 1 configured as described above will be described.
When a drive current is supplied from the power supply brush 18 to the commutator piece 15 to which the power supply brush is pressed and contacted, the drive current is also supplied to the commutator piece 15 connected via the short-circuit conductor 21, It is supplied to the winding 14 connected to the commutator pieces 15. Then, the armature 1 is rotationally driven by exchanging magnetic flux between the armature 1 and a stator magnet provided in a housing (not shown).

Next, the characteristic effects of the above embodiment will be described below.
(1) The short-circuit conductor 21 is formed seamlessly, and both end portions 21a thereof are electrically connected to the commutator piece 15 inside the outer peripheral surface of the commutator piece 15, so that the short-circuit conductor 21 is connected to the connection claw portion 24c. The increase in size can be suppressed without using the surrounding space, and the number of electrically connected portions can be suppressed by the short-circuit conductor 21 without a joint.

  (2) Since the groove part 15a which can insert the edge part 21a of the short circuit conductor 21 is formed in the axial direction edge part of the commutator piece 15, positioning of the short circuit conductor 21 with respect to the commutator piece 15 becomes easy. Therefore, for example, the commutator 13 can be easily manufactured by performing welding after positioning.

  (3) Since the intermediate part 21b is embed | buried under the insulating material 23 and those space | intervals are hold | maintained for the some short circuit conductor 21, while being able to ensure the insulation state of the short circuit conductors 21, handling becomes easy. .

  (4) A connection claw member 24 that protrudes radially outward of the commutator piece 15 to form a connection claw portion 24c that is engaged with the winding 14 and is electrically connected to the commutator piece 15 and the short-circuit conductor 21. In order to provide, the connection nail | claw part 24c can be provided only in the required location. Thereby, all the commutator pieces 15 can be made into the same shape, for example, the waste at the time of manufacturing the commutator pieces 15 from a board | plate material can be eliminated. In other words, when the plate material for manufacturing a plurality of commutator pieces has a connection claw that is folded back from the commutator piece, a plate material having a length before being turned back is required, and a portion other than the portion where the connection claw is required Although the plate material is largely wasted, the waste can be eliminated.

  (5) The connection claw member 24 has an insertion hole 24a through which the end portion 21a of the short-circuit conductor 21 is inserted in the base portion 24b, and the base portion 24b is sandwiched between the commutator piece 15 and the insulating material 23. While being able to make favorable electrical connection with the child piece 15 and the short-circuit conductor 21, it can hold | maintain firmly.

  (6) In the “winding step”, the conductor wire D is sequentially wound in a jig pattern 31b between the protrusions 31a of the short-circuit conductor forming jig 31 in a preset pattern. In the “cutting step”, the short-circuit conductor forming treatment is performed. When the conductor wire D on one side of the tool 31 is cut and removed, a plurality of short-circuit conductors 21 having no joints are formed. In this way, it is possible to simultaneously form a plurality of short-circuit conductors 21 each having no joint at a predetermined position.

  (7) In the “short-circuit conductor embedding step”, a part of the conductor wire D whose arrangement is held by the short-circuit conductor forming jig 31 is covered with the insulating material 23. Therefore, it can be set as the state which kept the space | interval of the some short circuit conductor 21 easily, while being able to ensure the insulation state of the short circuit conductors 21, it becomes easy to handle.

The above embodiment may be modified as follows.
In the above embodiment, the groove 15a into which the end 21a of the short-circuit conductor 21 can be inserted is formed at the axial end of the commutator piece 15. However, both ends of the short-circuit conductor 21 are respectively commutator pieces. As long as it is electrically connected to the commutator piece 15 on the inner side of the outer peripheral surface 15, the commutator piece without the groove 15 a may be used. For example, you may connect the both ends of the short circuit conductor 21 to the axial direction end surface of a commutator piece, respectively.

In the above embodiment, the plurality of short-circuit conductors 21 are configured such that the intermediate portion 21b is embedded in the insulating material 23, but is not limited thereto, and may be configured without providing the insulating material 23.
In the above embodiment, the connection claw portion 24c is formed and the connection claw member 24 electrically connected to the commutator piece 15 and the short-circuit conductor 21 is provided. However, the present invention is not limited thereto. May be formed integrally with the commutator piece 15.

  In the above embodiment, the connection claw member 24 has the insertion hole 24a through which the end portion 21a of the short-circuit conductor 21 is inserted in the base portion 24b, and the base portion 24b is sandwiched between the commutator piece 15 and the insulating material 23. However, the present invention is not limited to this. For example, a configuration in which the commutator piece 15 is simply fixed to the side surface may be employed.

-The manufacturing method of the said embodiment may be changed, for example, a "cutting process" may be performed after a "winding process", and a "short circuit conductor embedding process" may be performed after that.
In the above embodiment, the connection claw member 24 is made of a plated brass material, but may be changed to another material if it is a conductive member.

  In the above embodiment, the armature core 12 has 12 slots having 12 teeth, and the commutator 13 has 24 commutator pieces 15. It may be changed.

  DESCRIPTION OF SYMBOLS 14 ... Winding | winding, 15 ... Commutator piece, 15a ... Groove part, 16 ... Main body insulating material, 17 ... Commutator main body, 21 ... Short-circuit conductor, 21a ... End part, 21b ... Middle part, 23 ... Insulating material, 24 ... Connection Claw member, 24a ... insertion hole, 24b ... base, 24c ... connection claw part, 31 ... short circuit conductor forming jig, 31a ... projection, 31b ... jig groove part, D ... conductor wire.

Claims (7)

A commutator body having a plurality of commutator pieces disposed in the circumferential direction and a body insulating material disposed to hold the commutator pieces radially inward of the commutator pieces;
A commutator provided at an axial end of the commutator body and provided with a plurality of short-circuit conductors that electrically connect the separated commutator pieces,
The short-circuit conductor is formed seamlessly, and both ends thereof are electrically connected to the commutator piece inside the outer peripheral surface of the commutator piece, respectively. The commutator according to claim 1,
The commutator is characterized in that a groove portion into which an end portion of the short-circuit conductor can be inserted is formed at an axial end portion of the commutator piece. The commutator according to claim 1 or 2,
A plurality of the short-circuit conductors are characterized in that intermediate portions are embedded in an insulating material and the distance between them is maintained. The commutator according to any one of claims 1 to 3,
A connection claw member that protrudes radially outward of the commutator piece to form a connection claw portion that locks the winding is formed, and is provided with a connection claw member that is electrically connected to at least one of the commutator piece and the short-circuit conductor. A commutator characterized by. A commutator according to claim 4 when dependent on claim 3,
The wiring claw member has an insertion hole through which an end portion of the short-circuit conductor is inserted at a base portion thereof, and the base portion is sandwiched between the commutator piece and the insulating material. A commutator body having a plurality of commutator pieces disposed in the circumferential direction and a body insulating material disposed to hold the commutator pieces radially inward of the commutator pieces;
A method of manufacturing a commutator comprising a plurality of short-circuit conductors that are provided at axial ends of the commutator body and electrically connect the separated commutator pieces,
A winding step of sequentially winding a conductor wire in a predetermined pattern in a jig groove between the protrusions in a plate-like short-circuited conductor forming jig having a plurality of protrusions radially;
After the winding step, a cutting step of forming a plurality of short-circuited conductors without seams by cutting and removing the conductor wire on one side of the short-circuiting conductor forming jig,
A method of manufacturing a commutator comprising: a connecting step of electrically connecting both ends of the short-circuit conductor to the commutator piece inside the outer peripheral surface of the commutator piece after the cutting step, respectively. . In the manufacturing method of the commutator according to claim 6,
After the winding step, before the cutting step, or after the cutting step, insulate the part of the conductor wire or the short-circuit conductor whose arrangement is held by the short-circuit conductor forming jig A commutator manufacturing method comprising a short-circuit conductor burying step of covering with a material.