JP3378829B2 - Method of manufacturing motor end frame and motor component - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a motor end frame and a motor component.

[0002]

2. Description of the Related Art Conventionally, an end frame of a motor is fitted in one side opening of a bottomed cylindrical core to accommodate an armature together with the core and to rotate a rotating shaft of the armature. It is configured to support. Further, a brush holder is provided on this end frame.

By the way, the end frame body is formed by deep-drawing an iron plate, and the brush holder is formed of resin because insulation is required. And
An end frame is formed by integrally connecting an iron plate end frame body and a synthetic resin brush holder.

As a method of molding the end frame made of the different materials, when the brush holder is manufactured as a separate part, a connecting projection is formed. On the other hand, the end frame body is formed with a hole into which the protrusion is fitted.
Then, with the protrusion fitted in the hole, the protrusion is crushed by means such as heat staking to integrally connect the end frame body and the brush holder.

By the way, the applicant of the present invention previously disclosed in Japanese Patent Laid-Open No. 9-1
Japanese Patent No. 63689 proposes a method of manufacturing an electric motor capable of reducing the size of a process transfer facility for transferring an assembly part or a subassembly. In this method, the hoop material is passed through a press machine, and the press machine forms a base part on the hoop material. The base parts formed on the hoop material are the yoke housing and the end frame. The yoke housing is formed by deep drawing at regular intervals in the longitudinal direction. Also, the end frame,
It is formed by deep drawing at regular intervals in the longitudinal direction so as to be juxtaposed with the yoke housing.

Then, the hoop material on which the yoke housing and the end frame are formed is conveyed to each assembling step, and an assembling part or a half part is attached to the yoke housing and the end frame formed on the hoop material at each assembling step. It is designed to be assembled.

[0007]

By the way, in the above-described motor manufacturing method, there is a step of integrally providing the brush holder to the end frame body formed of the hoop material. When the brush holder is connected to the end frame body formed by continuously forming a plurality of hoop members by the above-described method, a step of fitting the protrusion into the hole and a step of crushing the protrusion are required, which shortens the manufacturing time and reduces the manufacturing time. This was a problem in reducing the number of processes.

Moreover, in order for the brush holder connected to the end frame body to be firmly connected to any force applied from any direction, a large number of protrusions and holes for fitting the protrusions are required. The crushing process is complicated and takes time.

Further, in the above-mentioned manufacturing method, it is required to manufacture the motors in which only the shapes of the end frames are slightly different from each other in parallel due to the restriction of the mounting position of the motor.
In this case, the production is performed on separate production lines, and the equipment becomes large in scale, and the production efficiency is poor.

An object of the present invention is to provide a method for manufacturing an end frame of a motor and a motor component which can surely connect and fix the end frame main body and the brush holder and can downsize the motor.

It is an object of the present invention to provide a method of manufacturing a motor component, which allows a brush holder to be provided in a short time with respect to a plurality of brush holder bodies formed on a hoop material without increasing the number of manufacturing steps. .

An object of the present invention is to provide a method of manufacturing a motor component that can mold end frames having different outer shapes without increasing the number of manufacturing steps.

[0013]

According to a first aspect of the present invention, a cutout is formed on one side of an end frame body having a boss forming a bearing accommodating portion, and an insulating material is formed in the cutout. a end frame of the motor formed by outsert molding become more brush holder, a bent piece is rolled out and bent from the notch center portion of the edge of the front Symbol notch is inherent in the brush holder, wherein
The notches are formed on both sides of the bent piece.
The gist of the present invention is to provide a concave portion embedded in the brush holder .

According to a second aspect of the present invention, in the end frame of the motor according to the first aspect, the brush holder includes a support boss on an outer peripheral surface of a boss portion of the end frame body and an outer peripheral surface of the boss portion. The gist of the invention is to provide a resin introduction hole for forming the same material as the above.

According to a third aspect of the present invention, the bearing accommodating portion is formed.
Cut on one side of the end frame body with the boss
A notch is formed, and the notch is made of insulating material.
Of the motor formed by outsert molding
An end frame, which constitutes the brush holder
Attach the upper surface of the side wall and the outer surface of the upper wall to the end frame.
It characterized in that it is formed such that the outer surface flush the arm body.

According to a fourth aspect of the present invention, a cutout portion is formed on one side of the end frame body having the boss portion forming the bearing accommodating portion, and the cutout portion is made of a molding resin made of an insulating material. the brush holder a motor component manufacturing method of the formed by outsert molding, the notch of the notch extending from the central portion of the edge and the bent pieces which are bent provided Rutotomoni, the said notch Fold
The brush holder is formed on both sides of the bending piece.
The gist of the invention is to form a recess to be embedded, and to embed the recess in the brush holder when the outsert molding is performed , and to embed the recess in the brush holder molding resin.

According to a fifth aspect of the present invention, there is provided the motor component manufacturing method according to the fourth aspect, wherein a resin introducing hole is formed on an outer surface of the end frame body around the boss portion, and outsert molding is performed. At that time, the gist is that the supporting boss is formed of the brush holder molding resin on the outer peripheral surface of the boss portion through the resin introducing hole.

(Operation) According to the invention described in claim 1,
A bent piece that extends from the cutout edge of the cutout portion of the end frame body and is bent and formed is contained in the brush holder, and a recess formed on the outer surface extending from the cutout edge of the cutout portion of the end frame body is formed. By embedding in the brush holder molding resin, the connection between the brush holder and the end frame body is firmly connected. Further, since the recess is embedded in the brush holder molding resin, the brush holder molding resin does not project from the outer surface of the end frame body.

According to the second aspect of the invention, since the brush holder and the supporting boss are integrally formed through the resin introducing hole, the connection between the brush holder and the end frame body is more firmly connected. It

[0020]

According to the fourth aspect of the present invention, since the brush holder is formed by outsert molding with respect to the plurality of end frame bodies formed by continuous drawing on the hoop material, the plurality of end frames are formed. The brush holder can be formed on the frame main body at one time, and the manufacturing time and the number of manufacturing steps can be reduced. In addition, the bent piece extending from the cutout edge of the cutout portion of the end frame body and bent and formed is contained in the brush holder, and the concave portion formed on the outer surface extending from the cutout edge of the cutout portion of the end frame body is formed. Embedded in the brush holder molding resin, it is possible to manufacture an end frame in which the brush holder and the end frame body are firmly connected. Further, since the recess is embedded in the brush holder molding resin, the brush holder molding resin does not project from the outer surface of the end frame body.

According to the invention described in claim 5, the supporting boss can be formed simultaneously with the brush holder.

[0023]

1 is a perspective view showing the appearance of a small DC motor. In FIG. 1, a motor housing 2 of a motor 1 is composed of a yoke housing 3 and an end frame 4, and an armature is rotatably housed in a space formed by the yoke housing 3 and the end frame 4.

The end frame 4 has a cup shape as a whole, and as shown in FIG. 2, comprises an iron end frame body 5 and a brush holder 6 made of a synthetic resin made of an electrically insulating material. The end frame body 5 is, as shown in FIG.
A cylindrical boss portion 8 is formed in the central portion of the outer side surface 7. As shown in FIG. 1, the boss portion 8 is provided with a bearing 10 for supporting the rotating shaft 9 of the armature inside thereof. The end frame body 5 has a half cup shape in which one side is cut out to form a cutout portion 11, and a bending piece 12 is formed to extend from a central portion of a cutout edge 11a of the cutout portion 11. There is. The bending piece 12 has a triangular base portion 13 and a tip portion 14 extending from the tip of the base portion 13. The base portion 13 of the bent piece 12 is formed to extend so as to be flush with the outer side surface 7. Further, the tip end portion 14 of the bent piece 12 is bent downward from the base portion 13.

Further, the cutout edge 11 of the cutout portion 11
Notches 15 are formed on both sides of a. The cut 15 forms a rectangular space. At the entrance of the notch 15, a protrusion 16 is formed so as to extend so as to narrow the space.

The outer surface 7 of the protrusion 16 and its surroundings
Are recessed to form a first recess 17. Further, the outer peripheral surface of the notch 15 and the outer surface 7 on the opposite side of the first recess 17 are also similarly recessed to form a second recess 18. Therefore, in FIGS. 3 and 10, the first
The surfaces of the second recesses 17 and 18 are lower than the outer surface 7.

A resin introducing hole 19 is formed through the outer surface 7 of the end frame body 5 at a position facing each other with the boss portion 8 interposed therebetween. Also, a pair of resin introduction holes 19
Jig insertion holes 20 are formed at positions adjacent to each other.

Next, the brush holder 6 formed on the end frame body 5 will be described. The brush holder 6 is
It is formed on the cutout portion 11 side of the end frame body 5. The brush holder 6 has a base end portion with the cutout portion 1.
A side wall portion 21 is formed so as to extend forward from the one notched edge 11a and then extend downward. The bent piece 12 extending from the cutout portion 11 is provided inside the side wall portion 21. At this time, as shown in FIG. 8, the side wall portion 21 internally includes the tip portion 14 that is bent downward from the base portion 13 of the bent piece 12. That is, the side wall portion 21 is formed such that the upper side surface 22 thereof is flush with the outer side surface 7 of the end frame body 5.

On both sides of the upper portion of the side wall portion 21, there are formed upper wall portions 23 extending to the notch 15 side. The outside of the upper wall portion 23 closes the notch 15 and is embedded with the first and second recesses 17 and 18, and the outer surface 24 of the upper wall portion 23 is flush with the outer surface 7 of the end frame body 5. Is formed. The inner side of the upper wall portion 23 cooperates with the embedded portion in which the first and second recesses 17 and 18 are embedded, around the cut 15 and the protruding portion 16.
It is designed to sandwich. Therefore, the connection of the brush holder 6 having the side wall portion 21 and the upper wall portion 23 with respect to the end frame main body 5 in the vertical direction and the front-rear direction at the central portion becomes strong due to the presence of the bending piece 12. In addition, the vertical and front-rear connections to the end frame body 5 on both sides of the brush holder 6 are performed by embedding the embedded portion in which the first and second recesses 17 and 18 are embedded, the notch 15 and the protrusion 16 sandwiched. It becomes stronger by.

Further, as shown in FIG. 6, the inside of the upper wall portion 23 and the inside of the side wall portion 21 form a terminal accommodating portion 25. The terminal accommodating portion 25 accommodates a terminal integrally formed with a brush spring that holds a brush. Further, in the terminal accommodating portion 25, a male terminal through hole 26 penetrating the upper wall portion 23 and a female terminal through hole 27 penetrating the side wall portion 21 are formed.

A supporting boss 28 is formed on the outer periphery of the boss portion 8 of the end frame body 5. The supporting boss 28 is formed due to the restriction of the mounting position of the motor 1, and in the present embodiment, it is formed in order to increase the outer shape of the boss portion 8 to facilitate the support. In this embodiment, the support boss 28 is made of the same material as the brush holder 6, and is formed at the same time when the brush holder 6 is formed. That is, as shown in FIGS. 6 and 7, the supporting boss 28 has the brush holder 6 through the resin introducing hole 19.
Of the support boss 28, which is connected to the terminal housing portion 25 of the support boss 28 by being injected with resin through the resin introduction hole 19 when the brush holder 6 is formed by the outsert molding described later.
Is formed. Therefore, in this case, since the brush holder 6 is connected to the supporting boss 28 through the resin introduction hole 19, the brush holder 6 is more firmly connected to the end frame body 5.

Next, a method of manufacturing the end frame 4 will be described. In FIG. 15, the hoop material 31 is an iron strip-shaped plate material, and a plurality of end frame bodies 5 and the yoke housing 3 are formed at regular intervals in the longitudinal direction. The plurality of end frame bodies 5 and the yoke housing 3 formed on the hoop material 31 are formed by deep drawing using a press machine.

Then, this one hoop material 31 is transferred to an outsert molding step for forming the brush holder 6 on the end frame body 5 formed on the hoop material 31. Outsert molding is performed on each end frame main body 5 formed on the hoop material 31, and a mold for that is prepared.

FIG. 17 is a side cross-sectional view of a main part of a mold in which the mold is longitudinally cut in the longitudinal direction of the hoop material 31, and FIG. 18 is a sectional view of the mold in a direction orthogonal to the longitudinal direction of the hoop material 31. The cross section of the main part of the formed mold is shown.

The mold 32 comprises a lower mold 33 and an upper mold 34. The lower die 33 is disposed below the hoop material 31, and has a convex portion 35 for supporting the end frame body 5. The lower mold 33 includes the side wall portion 21, the upper wall portion 23,
A recess 36 for forming the brush holder 6 is formed from the terminal accommodating portion 25 and the like, and the supporting boss 28 is provided from the terminal accommodating portion 25 through the resin introducing hole 19.
A communication passage 37 is formed to form the.

On the other hand, the upper mold 34 is disposed on the upper side of the hoop material 31 and has a recess 38 for supporting the end frame body 5. Further, the upper mold 34 is formed with a recess 39 for forming the brush holder 6 and a recess 40 for forming the supporting boss 28. Then, the convex portion 35 and the concave portions 36, 38, 3
9, 40 and the communication passage 37 serve as cavities 41, 42 when the brush holder 6 and the supporting boss 28 are molded.

Further, as shown in FIG. 17, the runner 43 formed by the lower mold 33 and the upper mold 34 is formed from the gate 44 to the hoop material 31 so that a part of the hoop material 31 is interposed. . The runner 4 is attached to the upper mold 34.
3 is formed so that the resin is injected from the injection device through the introduction path 45.

Therefore, the resin injected through the introduction passage 45 is filled into the cavity 41 for molding the brush holder 6 through the runner 43 and the gate 44. Further, as shown in FIG. 18, a part of the resin filled in the cavity 41 is supported by the supporting boss 2 through the communication passage 37 and the resin introducing hole 19.
It is filled in the cavity 42 when molding 8.

Then, the resin filled in the cavities 41, 42 is cured. As a result, as shown in FIG. 16, each end frame main body 5 formed on the hoop material 31.
On the other hand, the brush holder 6 and the supporting boss 28 are simultaneously outsert-molded. At this time, gate 44 and runner 4
The resin cured in 3 forms a connecting body 46 that connects the side wall portion 21 of the brush holder 6 and the hoop material 31.

In this way, when the brush holder 6 is formed on each end frame body 5 of the hoop material 31 by outsert molding, the hoop material 31 is subjected to the next assembling step by a conveyor device such as a conveyor belt. Be guided. Then, in the assembling process, the assembly parts and the like are assembled to the respective end frame bodies 5 (end frames 4) in which the respective yoke housings 3 of the hoop material 31 and the brush holder 6 are formed. That is, an armature is attached to each yoke housing 3, and a terminal to which a brush is attached is attached to the end frame 4. Then, the end frame 4 is separated from the hoop material 31, the separated end frame 4 is caulked and fixed to the yoke housing 3 on the hoop material 31, and finally, the hoop material 31 is separated from the yoke housing 3
Are separated to complete the motor 1 shown in FIG.

When processing a plurality of end frame bodies 5 on the hoop material 31 with a press machine, the resin introduction hole 1
You may process the end-frame main body 5 which does not form 9. In this case, when the brush holder 6 is outsert-molded, the resin is not supplied to the cavity 42 for molding the supporting boss 28 because there is no resin introduction hole 19. Therefore,
As shown in FIG. 14, the end frame 4 without the supporting boss 28 can be formed. That is, it is possible to form the motor 1 corresponding to the case where the supporting boss 28 is unnecessary due to the restriction of the mounting position of the motor 1.

Next, the features of the embodiment configured as described above will be described below. (1) In the present embodiment, the brush holders 6 are formed by outsert molding on the plurality of end frame bodies 5 that are continuously drawn on the hoop material 31. Therefore, unlike the prior art, the work steps such as the work of fitting and crushing the brush holders 6 to the plurality of end frame bodies 5 one by one are eliminated, and the manufacturing time and the manufacturing process can be shortened.

(2) In the present embodiment, the bending piece 12 is provided which extends from the cut-out edge 11a of the cut-out portion 11 of the end frame body 5 and is bent, and the tip portion 14 of the bent piece 12 is attached to the brush holder. 6 was made to exist in the side wall part 21. Therefore, the central portion of the brush holder 6 and the end frame body 5 are firmly connected to each other with respect to vertical and longitudinal forces.

(3) In this embodiment, the outside of the upper wall portion 23 of the brush holder 6 is the cut 1 of the end frame body 5.
5, the first and second recesses 17 and 18 are buried, and the inside of the upper wall portion 23 cooperates with the buried portion in which the first and second recesses 17 and 18 are buried to surround the notch 15 and the protruding portion. 16 was sandwiched. Therefore, the both side portions of the brush holder 6 and the end frame body 5 are firmly connected to each other with respect to the force in the up-down direction and the front-back direction.

(4) In this embodiment, since the brush holder 6 and the supporting boss 28 are integrally formed via the resin introducing hole 19, the connection between the brush holder 6 and the end frame body 5 is further strengthened. Connected to.

(5) In this embodiment, although the brush holder 6 is formed by outsert molding, the upper side surface 22 of the side wall portion 21 and the outer side surface 24 of the upper wall portion 23 constituting the brush holder 6 are formed. Was formed so as to be flush with the outer surface 7 of the end frame body 5. That is, since the brush holder 6 is not projected outward from the outer side surface 7 of the end frame body 5, the motor 1 can be downsized.

(6) In this embodiment, the mold 32 has the cavity 41 for molding the brush holder 6 and the cavity 42 for molding the supporting boss 28.
Further, the cavity 42 of the supporting boss 28 is formed in the mold 32 through the resin introducing hole 19 formed in the end frame body 5.
A communication path 37 for introducing the resin from the cavity 41 of the brush holder 6 is formed. Therefore, the support boss 28 can be formed at the same time when the brush holder 6 is formed.

(7) The mold 32 of this embodiment is constructed so that the resin is introduced into the cavity 42 of the supporting boss 28 through the resin introducing hole 19 formed in the end frame body 5. Therefore, the resin introduction hole 1 is formed in the end frame body 5.
Outsert molding of the end frame main body 5 without 9 can form the end frame 4 without the supporting boss 28 as shown in FIG. That is, it is possible to form the end frame 4 having the supporting boss 28 shown in FIG. 2 and the end frame 4 having no supporting boss 28 shown in FIG. 14 with one die 32.

The embodiment of the invention is not limited to the above embodiment, but may be carried out as follows. In the above embodiment, the yoke housing 3 is also formed on the hoop material 31, but a hoop material on which only the end frame body 5 is formed may be used. Also in this case, the same effect as that of the above-described embodiment is obtained.

The numbers of the yoke housing 3 and the end frame body 5 formed on the hoop material 31 of the above embodiment are not particularly limited and may be changed appropriately.
Further, the hoop material 31 does not have to have a finite length, and may have a strip-like shape wound in a roll shape.

[0051]

According to the invention described in claims 1 and 2,
The brush holder can be firmly connected to the end frame body, and the motor can be downsized.

[0052] According to the invention described in 請 Motomeko 4, the production time
And the number of manufacturing steps can be reduced, the connection between the brush holder and the end frame body can be strengthened, and the motor can be downsized.

According to the invention of claim 5, claim 4
In addition to the effect of the invention described in (1), the brush holder and the supporting boss can be formed at the same time.

[Brief description of drawings]

FIG. 1 is a perspective view of a motor for explaining an embodiment.

FIG. 2 is a perspective view of an end frame.

FIG. 3 is a perspective view of an end frame body.

FIG. 4 is a plan view of an end frame.

FIG. 5 is a front view of the end frame.

FIG. 6 is a bottom view of the end frame.

FIG. 7 is a front sectional view of an end frame.

FIG. 8 is a side sectional view of the end frame.

FIG. 9 is a plan view of the end frame body.

FIG. 10 is a front view of the end frame body.

FIG. 11 is a bottom view of the end frame body.

FIG. 12 is a front sectional view of the end frame body.

FIG. 13 is a side sectional view of the end frame body.

FIG. 14 is a perspective view of an end frame without a supporting boss.

FIG. 15 is a perspective view of the hoop material before forming the brush holder.

FIG. 16 is a perspective view of the hoop material after the brush holder is molded.

FIG. 17 is a side sectional view of an essential part for explaining a brush holder molding die.

FIG. 18 is a front sectional view of an essential part for explaining a brush holder molding die.

[Explanation of symbols]

1 ... motor, 2 ... motor housing, 3 ... yoke housing, 4 ... end frame, 5 ... end frame body,
6 ... Brush holder, 7 ... Outer side surface, 8 ... Boss part, 11 ... Notch part, 11a ... Notch edge, 12 ... Bending piece, 1
3 ... Base part, 14 ... Tip part, 15 ... Notch, 16 ... Projection part, 17 ... 1st recessed part 17, 18 ... 2nd recessed part, 19 ... Resin introduction hole, 21 ... Side wall part, 22 ... Upper side surface, 23 ... Above Wall part, 24 ... Outer surface, 25 ... Terminal accommodating part, 28 ... Supporting boss, 31 ... Hoop material, 32 ... Mold, 33 ... Lower mold,
34 ... Upper mold, 37 ... Communication passage, 41, 42 ... Cavity,
43 ... Runner, 44 ... Gate, 45 ... Introductory path, 46 ...
Connected body.

─────────────────────────────────────────────────── ─── Continuation of the front page (58) Fields surveyed (Int.Cl. ⁷ , DB name) H02K 5/08 H02K 13/00 H02K 15/02

Claims (5)

(57) [Claims] 1. A notch (1) on one side of an end frame body (5) having a boss (8) forming a bearing housing.
1) is formed, notch edge of the notch portion the brush holder (6) made of an insulating material (11) comprising an end frame of the motor formed by outsert molding, before Symbol notch (11) Center of (11a)
Both a bent piece (12) extending from the portion and bent, which is included in the brush holder (6) and the bent piece (12) of the cutout portion (11).
Embedded in the brush holder (6) formed on each side
And a recessed portion (17, 18) to be formed . 2. The end frame of the motor according to claim 1, wherein the outer frame (7) around the boss (8) of the end frame body (5) is supported on the outer peripheral surface of the boss (8). Boss (2
An end frame comprising a resin introduction hole (19) for forming 8) with the same material as the brush holder (6). 3. A boss portion (8) forming a bearing accommodating portion is provided.
The cutout (1
1) is formed, and the notch (11) is made of insulating material.
Forming brush holder (6) by outsert molding
The end frame of the motor, which is on the side wall portion (21) of the brush holder (6).
Front side surface (22) and outer side surface (24) of the upper wall surface (23)
Note that it is flush with the outer surface (7) of the end frame body (5).
A method of manufacturing a motor component, which is characterized in that 4. A notch (1) on one side of an end frame body (5) having a boss (8) forming a bearing housing.
1) is formed, and the notch (11) is a method for manufacturing a motor component, in which the brush holder (6) is formed by outsert molding using a molding resin made of an insulating material. Center of notch edge (11a)
Bending pieces (12) extending from the portion and bent and formed
It said of provided Rutotomoni, the notch (11) folding
The brushes formed on both sides of the bending piece (12), respectively.
Forming recesses (17, 18) embedded in the holder (6)
During the outsert molding, the recesses (17, 18) are filled with the brush holder molding resin, and the bent pieces (12) are made to be internally contained in the brush holder (6). Motor parts manufacturing method. 5. The method of manufacturing a motor component according to claim 4, wherein a resin introducing hole (19) is formed in an outer side surface (7) around the boss portion (8) of the end frame body (5). During the outsert molding, the supporting boss (28) is formed from the brush holder molding resin on the outer peripheral surface of the boss portion (8) through the resin introducing hole (19). Manufacturing method of motor parts.