JP3538068B2 - Motor manufacturing method - 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, and more particularly, to a method for attaching a surge absorbing element used for eliminating noise to a riser portion.

[0002]

2. Description of the Related Art A motor includes a commutator provided on a rotor,
There is one configured to electrically connect the rotor side and the stator side via a brush provided on the stator. The spark discharge generated between the commutator and the brush during the operation of the motor generates undesired electric noise in terms of the function of the motor and the operation of the surrounding electronic devices. It may cause deterioration of performance.
Therefore, in order to suppress the occurrence of such a spark discharge, a surge absorbing element such as a ring-shaped varistor is attached to three commutator pieces constituting a commutator.

In order to attach a ring-shaped varistor to a commutator piece, an electrode provided on an outer peripheral surface of the varistor and a riser portion radially extended from each commutator piece are soldered. In this soldering step, cream solder is applied in advance to the contact portions between the varistor and the three risers, and the contact portions are irradiated with an optical beam to melt and solidify the solder, thereby forming a varistor. The riser is joined. As shown in FIG. 5, a conventional motor manufacturing process line 71 includes a belt conveyor 72 for transporting the rotor 11 and a heating worktable 73 for mounting the rotor 11 thereon. The line 71 is provided with three heating devices 74a, 74b, and 74c, and performs a soldering operation by heating different contact portions of one rotor 11 for each of the heating devices 74a to 74c. The heating device 74 uses a xenon lamp 75 as a light source, and irradiates the converged optical beam with a condensing lens 76 on each contact portion. Since the three contact portions requiring soldering are set at predetermined angular intervals, the irradiation directions of the optical beams of the heating devices 74a to 74c are set to be different from each other accordingly.

When the three contact portions are soldered, first, one rotor 11 is firstly moved by the belt conveyor 72 to the first position.
Is transferred to a position corresponding to the heating device 74a, the belt conveyor 72 is stopped, and the rotor 11 is moved onto the heating worktable 73 by a robot (not shown) or the like. Then, a soldering operation of the first contact portion is performed by the first heating device 74a. Next, the rotor 11 is moved to the belt conveyor 72 and transported to a position corresponding to the second heating device 74b, and then the second contact portion is similarly soldered. Further, when the soldering work of the third contact portion is performed by the third heating device 74c, the soldering work of all the contact portions is completed.

[0005]

However, in the motor manufacturing line 71, the heating devices 74a to 74c are used.
Is a spot irradiation type, so that the soldering operation must be performed for each contact portion. Therefore, each time the soldering operation is performed, the rotor 11 is moved to the belt conveyor 7.
2 and the heating workbench 73,
Each time, the belt conveyor 72 must be stopped.
For this reason, the number of man-hours per motor increases, resulting in a problem that the cost is increased.

An object of the present invention is to provide a method of manufacturing a motor which enables continuous machining at low cost.

[0007]

In order to solve the above-mentioned problems, according to the first aspect of the present invention, there is provided a motor for fixing a ring-shaped surge absorbing element to an outer periphery of a commutator body of a motor rotor. a manufacturing method, the contact portion between the riser portion formed to extend radially from the commutator body and the ring-shaped surge absorbing element, in the state in which the pre-cream solder is applied, the conveying path before Symbol abutment portion An optical beam band formed to extend along the transport trajectory in the upper fixed section,
While the rotor is being transported by the transport device ,
The ring-shaped surge absorbing element and the riser portion are soldered by irradiating the ring-shaped surge absorbing element.

Therefore, according to the first aspect of the present invention,
While the rotor is moving along the conveyor, the optical beam band illuminates the abutting portion, and the abutting portion can be continuously soldered.

According to a second aspect of the present invention, in the motor manufacturing method of the first aspect, the optical beam band is
It is formed by a light source arranged along the transport trajectory of the contact portion, and a reflecting mirror arranged around the light source. Therefore, just by moving the rotor below the light source along the transport device, the optical beam band is irradiated to the contact portion,
The work of soldering the contact portion can be performed, and the position and size of the optical beam band can be set by the reflecting mirror.

According to a third aspect of the present invention, in the method for manufacturing a motor according to the second aspect, the light source is a halogen lamp. Therefore, the light source can be provided at low cost, and it is safe for the human body.

According to a fourth aspect of the present invention, in the method of manufacturing a motor according to the third aspect, the halogen lamp emits near-infrared rays. Accordingly, different materials can be uniformly heated by the near-infrared rays and the temperature required for soldering can be provided.

According to a fifth aspect of the present invention, in the method for manufacturing a motor according to any one of the first to fourth aspects,
The rotor has a rotating shaft, and the commutator body includes three commutator pieces arranged around the rotating shaft. Each commutator piece has the riser portion, and each riser portion and the ring-shaped surge Three abutting portions are formed between the absorbing element and the abutting portion, wherein the optical beam band includes a first optical beam band illuminating one of the three abutting portions and two abutting portions. And a second optical beam band illuminating the portion.

Therefore, according to the invention described in claim 5,
Since three contact portions can be soldered by two optical beam bands for one rotor, work can be performed efficiently.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of a motor manufacturing method embodying the present invention will be described below with reference to FIGS.

As shown in FIG. 1, a rotor 11 constituting a motor includes a core 13 attached to a rotating shaft 12, and a winding 14 is wound around the core 13. A commutator body 15 is provided on the rotating shaft 12, and the commutator body 15 is composed of three commutator pieces 15a. Each commutator piece 15
a is mounted on the rotating shaft 12 via a cylindrical insulating member 16. A riser portion 20 is formed radially on the winding 14 side of each commutator piece 15a, and extends 120 ° from each other.
Are arranged at intervals. The riser section 20 includes distal ends 21 bent at right angles, and the windings 14 corresponding to the respective distal ends 21 are wound therearound. A varistor 25, which is a ring-shaped surge absorbing element, is mounted on these riser sections 20, and the varistor 25 is arranged on the outer periphery of the commutator body 15 in this state. Three electrodes 26 are formed on the outer peripheral surface of the varistor 25, and come into contact with the inner portions of the distal end portions 21 of the riser portions 20, respectively. Cream solder is applied between the distal end portion 21 of each riser section 20 and the contact portion of the corresponding electrode 26, and then the contact portion is soldered.

Next, a method of soldering the contact portion will be described. As shown in FIG. 2, in a motor manufacturing process line 31, a plurality of rotors 11 are placed on a base 33, respectively, and a belt conveyor 32 as a transport device moves on the line 31 in a direction indicated by an arrow. Conveyed. At this time, the rotor 11 is positioned in advance so that the rotor 11 is not easily displaced with respect to the base 33 during transportation.

Above the line 31, a pair of line-type ramps 34a and 34b are provided in parallel on the trajectory of the rotor 11 and fixedly supported by a support frame (not shown). The rotor 1 is located below the lamps 34a and 34b.
1 is passed. As shown in FIGS. 2 and 3, a halogen lamp 35 for generating an optical beam band is provided in the line type lamps 34a and 34b, and emits a near infrared beam. Here, the near infrared beam has a wavelength of about 0.8 μm to 2 μm and a heating element temperature of about 3000 ° C. to 1600 ° C. The heat generation temperature of the halogen lamp 35 of this embodiment is about 300
The temperature is set to be 0 ° C. Line type lamp 3
On the inner peripheral surfaces of 4a and 34b, there is provided a reflecting mirror 36 having a substantially semicircular cross section made of brass and plated with gold. The reflecting mirror 36 reflects and condenses the near-infrared beam emitted from the halogen lamp 35. , A near-infrared beam band is generated, and the beam band is irradiated to the contact portion between the tip end 21 of the riser unit 20 and the electrode 26. The temperature of the near-infrared beam band when irradiating the contact portion is up to about 1200 ° C.
The temperature is high enough to melt the cream solder applied to the contact portion. When the rotor 11 passes below the line type lamps 34a and 34b, the near-infrared beam band is irradiated on the rotor 11 in the irradiation ranges 37a and 37b shown in FIG. That is, the line type lamp 34
a irradiates the beam band to two contact portions in the irradiation range 37a, while the line type lamp 34b irradiates the beam band to one contact portion in the irradiation range 37b. Note that the shape and size of the beam band in both irradiation ranges 37a and 37b are specified by the shape of the reflecting mirror 36. The line-type lamps 34a and 34b are provided with pipes 38 for circulating cold water, respectively.
Line type lamps 34a, 34 are provided by halogen lamp 35.
b prevents overheating.

Accordingly, while the rotor 11 is being conveyed by the belt conveyor 32, the tip 21 of the riser 20 and the electrode 26
Is heated by the near infrared beam band, the cream solder applied to the contact portion is melted, and the contact portion is filled with the molten solder. Then, after passing through the line type lamps 34a and 34b, the contact portion is naturally cooled, and the soldering is completed.

According to the motor manufacturing method of the above embodiment, the following effects can be obtained. (1) In the above embodiment, the line type lamps 34a, 34
The soldering operation can be performed while the rotor 11 is moving along the line 31 below b. Therefore, continuous processing can be performed without stopping the belt conveyor for performing the soldering operation for each contact portion. Therefore, the number of steps per motor is reduced, and as a result, the manufacturing cost of the motor can be reduced.

(2) Since three contact portions can be soldered by two near-infrared beam bands for one rotor 11, work can be efficiently performed. Particularly, in the present embodiment, since the irradiation ranges 37a and 37b are set to be narrow, it is possible to prevent other portions of the rotor 11 from being heated.

(3) The position and size of the optical beam band can be set by the reflecting mirror 36 provided on the line type lamps 34a and 34b, and it is possible to cope with the manufacture of motors of various sizes.

(4) Since the halogen lamp 35 that emits near-infrared light is used as the light source, the light source can be provided at a low cost and is safe for the human body. Further, it is possible to uniformly heat different kinds of materials and to provide a temperature necessary for melting the cream solder.

The above embodiment may be modified as follows. In the above embodiment, the halogen lamp 35 that emits a near-infrared beam is used, but a mid-infrared beam or a far-infrared beam may be used. Here, the mid-infrared ray has a beam wavelength of about 2 μm to 4 μm and a heating element temperature of about 1600 ° C. to 500 ° C. Also,
Far-infrared rays have a beam wavelength of about 4 μm to 1000 μm and a heating element temperature of about 500 ° C. or less. In particular, such a change is useful when the melting temperature of the cream solder and the material of the riser portion 20 and the electrode 26 are changed. In the above embodiment, two line lamps are used, but three line lamps may be used to irradiate each of the three contact portions. Further, only one line type lamp may be used. In this case, rotor 1
It is also possible to irradiate three contact portions by rotating the base 33 by 120 ° at a time when 1 passes through the line 31. On the other hand, separately from this, it is also possible to use only one line-type lamp so as to extend the irradiation range so as to irradiate all three contact portions. -The installation angles of the line type lamps 34a and 34b may be variable. In this case, the positions of the irradiation ranges 37a and 37b can be appropriately changed even for the rotor 11 having a different size. In this case, one line 31
Accordingly, it is possible to cope with the manufacture of motors having different sizes. Note that the installation angle adjustment may be configured such that a plurality of installation angles are stored in advance in accordance with the type of the motor, and are appropriately selected and used by computer control.

Next, technical ideas other than those described in the claims which can be understood from the above-described embodiment and other examples will be described below together with their effects. (1) The method for manufacturing a motor according to any one of claims 1 to 5, further comprising an optical beam band adjusting mechanism configured to change the shape and size of the optical beam band. In this case, it is possible to appropriately cope with the manufacture of motors having different sizes. The adjustment of the optical beam band by the optical beam band adjustment mechanism includes a change in the installation angle of the halogen lamp, the distance from the irradiation object, the shape of the reflecting mirror, and the like.

[0025]

As described above in detail, according to the first aspect of the present invention, the optical beam band irradiates the abutting portion while the rotor is moving along the transporting device. The soldering operation of the contact portion can be performed continuously. Therefore, the number of steps per motor is reduced, and as a result, the manufacturing cost of the motor can be reduced.

According to the invention described in claim 2, according to claim 1
In addition to the effects of the invention described in the above, by merely moving the rotor below the light source along the transfer device, the optical beam band can be applied to the contact portion, and the contact portion can be soldered. At the same time, the position and size of the optical beam band can be set by the reflecting mirror.

According to the invention described in claim 3, according to claim 2
In addition to the effects of the invention described in (1), the light source can be provided at low cost, and it is safe for the human body. According to the invention set forth in claim 4, in addition to the effect of the invention set forth in claim 3, it is possible to uniformly heat different kinds of materials by near infrared rays and to provide a temperature required for soldering.

According to the fifth aspect of the present invention, the first aspect is provided.
In addition to the effects of the inventions described in any one of (1) to (4), since three abutting portions can be soldered by two optical beam bands per one rotor, work can be performed efficiently.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view showing a rotor of a motor.

FIG. 2 is a schematic diagram showing a motor production line according to an embodiment of the present invention.

FIG. 3 is a schematic front view showing a positional relationship between an optical beam band and a motor.

FIG. 4 is a schematic plan view showing an irradiation state of an optical beam band.

FIG. 5 is a schematic diagram showing a conventional motor production line.

[Explanation of symbols]

11 ... rotor, 12 ... rotating shaft, 15 ... commutator body, 15
a: commutator piece, 20: riser part, 25: varistor as ring-shaped surge absorbing element, 32 ... belt conveyor as transport device, 35 ... halogen lamp as light source, 3
6 ... Reflection mirror.

────────────────────────────────────────────────── ─── Continuation of front page (56) References JP-A-10-163257 (JP, A) JP-A-6-170528 (JP, A) JP-A-9-254396 (JP, A) JP-A-6-254396 226436 (JP, A) JP-A-8-181427 (JP, A) JP-A-9-148037 (JP, A) JP-A-6-17367 (JP, U) JP-A 54-39507 (JP, U) (58) Field surveyed (Int. Cl. ⁷ , DB name) H02K 15/00-15/16 H02K 13/00-13/14

Claims (5)

(57) [Claims] 1. A method of manufacturing a motor for fixing a ring-shaped surge absorbing element to an outer periphery of a commutator main body in a rotor of a motor, comprising: a riser portion radially extending from the commutator main body and the ring; the contact portion between Jo surge absorbing element, in the state in which the pre-cream solder is applied, the pre-Symbol optical beam band formed so as to extend along the conveying path in a predetermined section on the transport trajectory of the contact portion, said by irradiating against the <br/> the contact portion while transporting the rotor by the transport device, a motor, characterized in that the said ring-shaped surge absorbing element and the riser portion to be soldered Production method. 2. The motor according to claim 1, wherein the optical beam band is formed by a light source disposed along a transport trajectory of the abutting portion, and a reflecting mirror disposed around the light source. Production method. 3. The method according to claim 2, wherein the light source is a halogen lamp. 4. The method according to claim 3, wherein the halogen lamp emits near infrared rays. 5. The rotor has a rotating shaft, and the commutator main body is composed of three commutator pieces arranged around the rotating shaft, each commutator piece having the riser portion, Three contact portions are formed between the portion and the ring-shaped surge absorbing element; and the optical beam band is a first optical beam band that irradiates one of the three contact portions with a contact portion. And a second optical beam band illuminating the two abutting portions.
A method for manufacturing a motor according to any one of claims 1 to 4.