JP2595129B2 - Combination structure of armature coil and commutator segment of rotating electric machine - Google Patents

Description

The present invention relates to a method of coupling an armature coil of a rotating electric machine and a commutator segment, and for example, relates to an armature coil suitable for a starting motor for starting an internal combustion engine. The present invention relates to a method for coupling with a commutator segment.

[Conventional technology]

It is widely known that an end of a coil of an armature is inserted into a mounting groove of a commutator piece to electrically connect the coil to the commutator piece (segment) by electric current caulking (fusing). For example, Japanese Patent Application Laid-Open No. 60-39342 discloses an attempt to improve the mechanical and electrical coupling between the coil and the segment after the current is swaged by devising the shape of the segment groove.

Japanese Patent Application Laid-Open No. 56-46647 discloses that in connecting a coil lead portion and a commutator segment, a contact portion between the lead portion of the armature coil and the lead portion is provided. After peeling off only the insulating film in the contact portion of (1), in other words, after removing the contact portion between the welding chip and the outlet portion and the portion in contact with the space after completion, ultrasonic welding,
Alternatively, a technique is disclosed in which coils (including a plurality of coils) and commutator segments are connected by performing electric resistance welding.

[Problems to be solved by the invention]

There is always a demand for smaller and lighter rotating electrical machines,
For example, the above demand for a starting motor for an internal combustion engine has been rapidly increasing due to a movement to improve fuel efficiency by reducing the weight of the entire vehicle. To cope with this, the armature is reduced in size and weight. One of the concrete measures is to use a flat wire to improve the space factor of the conductor coil inserted into the armature core with respect to the armature core slot groove. Things are done. Also, this conductor does not change its output even if it is small and lightweight,
Alternatively, a material having high heat resistance is used secondarily from the environment where it is necessary to further improve.

Such high heat resistance is imparted by the insulating enamel coating, and the electrical and electrical connection between the commutator segment and the coil outlet is improved.
Production problems arise in the mechanical connection. In the case where the step of peeling off the coating of the outlet portion of this type of coil by using a chemical does not cause the above-mentioned problem at the time of connection, usually, this type of chemical has a strong alkali as a main component and a liquid temperature. To
If the temperature is not set to about 500 ° C., a sufficient effect cannot be exerted, so that there is a problem that the operation is dangerous. In addition, the time required for the work is about one minute per one place, so that there is an economic problem in a situation where it is required to make one product in several seconds. In particular, when chemical stripping is performed before individual coils are incorporated into the armature core (in an individual state), the ability to strip very large numbers of coils is required, and the equipment becomes larger and more expensive. Cause the problem to say.

Therefore, it would be desirable if the connection could be made without peeling off the outlet of the coil. If it is attempted to melt the enamel, the coil member itself is insulated and does not conduct electricity or heat (heat generation), so it is necessary to reach a temperature at which the enamel can be softened and melted by heat generation and heating from the commutator segments, The temperature of the segments and the insulating resin in contact with the segments also becomes high, causing a problem that their strength is weakened. Further, even when the temperature at which softening and melting occurs, the fluidity of the molten enamel is poor, so that it remains without being removed from the contact surface between the coils or between the coil and the segment, so that good electrical connection cannot be obtained. There was a problem.

As described above, the problem to be solved by the present invention is to realize the electrical and mechanical connection of the high heat resistant enamel wire inserted into the segment groove of the commutator reliably and inexpensively. This requires successful melting and elimination of the high heat resistant enamel coating.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for joining an armature coil and a commutator segment of a rotating electric machine, which enables good electrical and mechanical connection of a coil coated with high-temperature resistance.

[Means for solving the problem]

The present invention relates to a rotating electric machine in which a lead portion of an armature coil is inserted into a groove portion of a commutator segment laminated in a radial direction, and an electrical and mechanical connection between the lead portion and the segment is performed by current caulking. In the method for coupling an armature coil and a commutator segment according to the above, each of the armature coil outlet portions is formed in advance by cutting a surface in a pressing electrode pressing direction to remove an insulator, and the cut surface is formed. This is achieved by crimping current through.

Preferably, the present invention is achieved by making the width of the insulator cutout surface of the armature coil outlet portion longer than the riser width of the commutator segments.

Preferably, the present invention is achieved by setting the upper insulator cutout surface of the armature outer coil outlet portion to be lower than the riser upper end surface of the commutator segment.

[Action]

The current passes through the coil conductor when the current is swaged. Is discharged. On the other hand, in the commutator, enamel discharge is promoted during energization crimping, and the remaining enamel is reduced, so that electrical and mechanical coupling is performed.

〔Example〕

FIG. 1 shows a front view of a cross section of a part of an armature to which the present invention is applied. The laminated armature core 2 is press-fitted into the outer diameter portion of the shaft 1 serving as the rotation axis, and a slot 2 a extending in the axial direction is provided inside the armature core 2. A slot insulating material 3a for securing insulation from the coil is inserted into the inner peripheral surface of the slot 2a, and the coil 4 is inserted and arranged inside the slot 2a from the left end side of the armature core 2.

On the left end face of the armature core 2, insulating materials 2a and 2 having substantially the same shape as the armature core 2 are used for the purpose of ensuring insulation if necessary.
b is provided. A commutator 5 is provided on the outer periphery of the right end of the shaft 1.
Is press-fitted. In the commutator 5, a conductor segment 5c is held in an annular shape via an insulator 5a around an outer periphery of a bush 5b directly pressed into the shaft 1, and the conductor segment 5c is
Punched and formed integrally with 5d is used.

The insulator 5a is generally formed by a mold member. The coil 4 is a rectangular coil formed in a substantially U-shape as shown in FIG. 7, and is inserted over several slots 2a provided in the armature core 2, one end of which is arranged on the outer peripheral side of the slot 2a. Thus, the outer coil 4a is formed, and the other end is disposed on the inner peripheral side of the slot 2a to form the inner coil 4b. Since the same number of coils 4 as the slots 2a are simultaneously inserted in this way,
In this example, two coil wires are inserted into each slot 2a.

The outer coil 4a and the inner coil 4b are respectively twisted in predetermined directions and angles outside the armature core 2 and housed in grooves provided in the riser 5d.

FIG. 2 is an axial sectional view of a segment and a riser portion to which the present invention is applied, and FIG. 3 is a side view of FIG. The outer coil 4a and the inner coil 4b already described
It is inserted into the groove provided in 5d. These coils 4a, 4
A cut surface 4c (hereinafter referred to as a cut portion 4c) that is longer than the width of the riser portion is provided on the upper surface and the lower surface in the drawing of FIG.
Is removed, and the conductor is exposed. On the other hand, the covering portion 4f remains on the side surface of each coil. An inclined guide portion 4e is provided at the tip end of each of the coils 4a and 4b, and preferably has an inclined shape also in a direction perpendicular to the paper surface by a method described later. This has the effect of easily and reliably inserting the coil 2 into the armature core 2. This also has the effect of making it easier for the coil to enter the riser groove when the commutator 5 is pressed into the shaft 1. Also, the guide section 4e
A straight portion 4d having an appropriate length and the original shape of the wire is left in a portion continuing from the left side to the right. This plays a role of regulating the position inside the slot insulating material 3 so that the cut portion 4c shown in FIG. 2 does not catch on the insertion of the coil 4 into the armature core 2.

Prior to the energization caulking operation, the right side of the riser portion 5d shown in FIG. 2 is selectively cut off from the right end. In this state, first, the bottom of the riser groove has an arc shape that is hardly a perfect rectangle for convenience of manufacture.
On the other hand, the formation of the cut portion 4c is performed substantially linearly in the left-right direction in FIG. For this reason, the riser groove bottom and inner coil 4b
Gap g ₁ is provided between the lower surface portion. Due to the contact with the coil material comrades near the left riser 5d also has an outer coil 4a and the inner coil 4b is removed riser right straight portion 4d for example in the riser grooves, also the space g ₂ is secured You. The depth of the riser groove is set such that the upper cut portion 4c of the outer coil 4a is lower than the riser upper end surface.

At the time of energizing and crimping, the pressurizing electrode 6a is installed so as to straddle the riser groove, the energizing electrode 6b is installed on the same segment, and a power source 7 that appropriately controls and applies a current between the electrodes 6a and 6b is provided. Is connected. Each of the two electrodes 6a and 6b is pushed toward the center of the shaft 1 with an appropriate force.
The contact area of the current-carrying electrode 6b with the segment 5c is made sufficiently larger than the cross-sectional area of the pressure electrode 6a, and consideration is given to reducing heat generation at the surface of the segment 5c.

The progress of energization caulking is performed as follows. The current that first enters from the pressurizing electrode 6a, which is in contact with the riser portion 5d of the pressurizing electrode 6a with a small area, passes through the path diffused near the riser groove, passes through the segment 5c, and passes through the conducting electrode 6b to the power supply. Will be returned. Of course, when the polarity of the electrode is reversed, the current flows in the opposite direction to that described above. In the case of alternating current, forward and reverse flows are performed alternately. Initially, since the area of the conductor portion in contact with the electrode 6a in the upper part (outer diameter side) of the riser 5d is small, rapid heating and softening of this part is performed, and the pressing electrode 6a A fall to the center side is performed. However, at this stage, the heating near the coil is not sufficiently performed, so that the covering portion 4f
Is not effectively performed. Heating inside riser groove
When the lowering of the pressing electrode 6a proceeds while performing softening and deformation,
The electrode 6a reaches the upper surface of the outer coil 4a, and further descends, and finally, the upper cut portion 4c of the outer coil 4a, the inner coil 4b is deformed to deform the electrode 6a, the upper surface of the outer coil 4a, the inner portion of the outer coil, and the outer coil. 6a lower cut portion, inner coil 4b upper cut portion,
Inside of inner coil, lower cut part of inner coil, segment
An electric path is formed by the bottom of 5c, and the outer and inner coils 4a and 4b are heated (heated). In this case, the coil is deformed selectively when the coil on the right side of the riser section 5d is left.
Starting at a substantially central portion of the width of 5d, if the coil on the right side of the riser 5d is selectively deleted, the process starts from the right portion of the coil.
In any case, in the initial stage, a gap is partially present between the riser 5d and the lower surface of the inner coil and between the outer and inner coils. In this state, heating (heating) of the coil itself is performed, so that the remaining insulator of the coating portion 4f is effectively heated and melted, and the melted insulator is discharged to the outside through the gap. This state progresses to a point where the outer and inner coils and the riser portion cannot be further deformed. As a result of an experiment in which the specifications of the pressing force and the current were appropriately selected, a small amount of the remaining insulator was present only as a carbide on the side surfaces of the coils 4a and 4b, and the electrical and mechanical connections were sufficiently performed. Have been done.

FIG. 4 shows an embodiment of a method for applying the present invention described above in mass production.

In the figure, the coil is sent from the left side, and the formation of the cut portion 4c and the guide portion 4e described with reference to FIG. 2 is performed using a press and a press die. It is appropriate to select the cut amount of the cut portion 4c so that the covering portion is deleted and the conductor portion is further deleted by about 0.1 to 0.5 mm. It is preferable that these shapes are formed by joining one coil and the end of the next coil. In the portion B which is further fed to the right side by a predetermined coil length, the inclined surface formation in the paper direction of the guide portion 4e described above with reference to FIG. 2 is performed using a press and a mold. At this time, as shown in a partially enlarged view, a mentry push for forming an angled chamfer 4g is performed in order to eliminate burrs generated when the cut portion 4c is formed.

Further, in the part c sent to the right side, the cutting into the coil material alone is also performed by the press and the mold. The coil material alone is formed into a coil 4 having a shape after entering the slot 2a by an appropriate forming machine.

According to the present embodiment, only the portion between the mutually contacting surfaces between the electrode, the coil, and the bottom of the segment, which forms an electric path in the machining direction at the time of energizing and crimping, is used as a conductor. Even if there is an insulating coating material in the side direction, effective heating and elimination of the coating material are performed, and if the coating material on the side surface is peeled in advance, the surface oxide This effectively eliminates heat from adhering foreign substances and the like, and makes desirable electrical and mechanical connections easily and reliably. Further, since the conductor surface of the coil material can be formed only by the two symmetrical surfaces, the required number of processes is minimized.

In order to realize these, the two symmetrical conductor planes can be formed in parallel by pressing to achieve extremely mass production and economical implementation. In addition, by removing the burrs generated by the press in advance, the insertion of the coil into the armature core does not occur, thereby enabling economical realization of automatic insertion and the like.

Furthermore, when a coil is inserted into the armature core, by providing a tapered shape portion for facilitating positioning, an economic effect such as automatic insertion occurs, and a deleted portion for forming a conductor and the armature core are provided with a tapered portion. By providing a non-deleted area between the coil and the tapered shape part to improve the insertability of the tip, the deleted part can be caught when inserting the coil into the armature core and when inserting the coil into the rectifier. Not
Work proceeds smoothly, and economic realization such as automation can be further achieved.

〔The invention's effect〕

According to the present invention, each of the armature coil outlets is
A cutting surface is formed in advance in the pressing electrode pressing direction surface by removing the insulating material, and current-tightening is performed through the cutting surface, so that the coil coated with high temperature resistance can be electrically and mechanically connected. Thus, the joining of the armature coil and the commutator segment of the rotating electric machine can be favorably performed.

[Brief description of the drawings]

FIG. 1 is a partially sectional front view of an armature to which the present invention is applied,
FIG. 2 is an axial sectional view of a segment and a riser portion to which the present invention is applied, FIG. 3 is a side view of FIG. 2, FIG. 4 is a perspective view of a coil material in a method of mass-producing the present invention, 5 is a sectional view taken along line VV of FIG. 4, FIG. 6 is a schematic side view of the armature core, and FIG. 7 is a perspective view of the coil. 1 ... shaft, 2 ... armature core, 2a ... slot,
4 ... Coil, 4a ... Outer coil, 4b ... Inner coil, 4c ...
... cut surface (cut part), 4d ... linear part, 4e ... guide part, 4f ... coating part, 5 ... rectifier, 5c ... segment
6 ... electrode, 7 ... power supply.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Shoji Suzuki 2520 Oji Takaba, Katsuta-shi, Ibaraki Co., Ltd. Inside the Sawa Plant of Hitachi, Ltd. Inside Hitachi, Ltd.Sawa Plant (72) Inventor Kiyomasa Tsubota Inside, Hitachi, Ltd.Sawa Plant, 2520 Takada, Kata-shi, Ibaraki

Claims (3)

(57) [Claims] 1. An armature coil having lead portions radially stacked and inserted into a groove of a commutator segment, and electrically and mechanically connected to the lead portion and the segment by current caulking. In the method of coupling an armature coil and a commutator segment of an electric machine, each of the armature coil outlets is cut in advance in a pressing electrode pressing direction surface to form a cut surface from which an insulator is removed, and the cut is performed. A method for coupling an armature coil and a commutator segment of a rotating electric machine, characterized by energizing and crimping through a surface. 2. The armature coil and commutator of a rotary electric machine according to claim 1, wherein the width of the insulation cut surface of the armature coil outlet is longer than the riser width of the commutator segment. How to combine segments. 3. An electric machine for a rotating electric machine according to claim 1, wherein the cut-out surface of the upper insulator of the armature outer coil outlet is set lower than the riser upper end surface of the commutator segment. A method of connecting a child coil and a commutator segment.