JP3936183B2 - Commutator and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a commutator and a method for manufacturing the commutator, and more particularly to a commutator and a method for manufacturing the commutator that can easily configure a complicated circuit such as a Y connection.
[0002]
[Prior art]
As prior examples according to the present invention, there are, for example, Japanese Utility Model Publication No. 62-37417 (preceding example 1) and Japanese Utility Model Publication No. 62-11188 (preceding example 2).
[0003]
[Problems to be solved by the invention]
The preceding example 1 has a commutator comprising a plurality of commutator pieces electrically connected to the outer peripheral surface of a commutator body made of an annular resin having an insertion hole for inserting a motor shaft. It is the structure provided with two or more groups. In the above configuration, the electrical connection of the plurality of commutator pieces is connected by connecting portions located on the outer peripheral surface of the commutator body, and the plurality of connecting portions are shafts of the commutator body. Since the configuration alternately intersects the direction, it is difficult to incorporate each commutator piece into the commutator body, and each commutator piece and the commutator body are merely joined together, so that high-speed rotation is possible. Sometimes there is a problem.
[0004]
In the prior example 2, when arranging a commutator group including a plurality of commutator pieces electrically connected to the outer peripheral surface of a cylindrical commutator body, a ring-shaped connection in which a plurality of commutator pieces are connected. The portion is stacked on the end face of the commutator body via an insulating plate. Therefore, there is a problem that it is necessary to produce an insulating plate separately and the number of parts increases, and the commutator body and the commutator piece are merely joined together, and there is a problem at high speed rotation. .
[0005]
[Means for Solving the Problems]
The present invention has been made in view of the conventional problems as described above, and a plurality of commutator pieces electrically connected to a commutator body made of resin having an insertion hole for inserting a shaft of a motor. A plurality of commutator groups are provided, and a plurality of connection bases are provided in the commutator body so as to be separated in the axial direction of the insertion hole, and a plurality of commutator pieces belonging to the same commutator group are connected in common. In the commutator that is electrically connected to the substrate ,
When each of the plurality of commutator pieces is provided in a continuous state and an annular commutator piece base having a coil connection portion corresponding to each of the parts to be divided is punched, the respective connections A connecting wire having a split piece in a state where the base is divided into a plurality of ends is integrally processed adjacent to each coil connecting portion, and each connecting wire is bent to belong to the same commutator group. Each of the connection bases is configured by connecting each of the divided pieces provided at the tip of the connection line of the commutator pieces in an annular shape so that the center of the commutator piece base is substantially coincident with the center. It is a feature.
[0006]
Further, in the method of manufacturing a commutator, an annular commutator piece base provided with a portion to be divided into a plurality of commutator pieces in a continuous state and provided with a coil connection portion corresponding to each of the portions to be divided. When the punching process is performed, a connection line provided with a divided piece in a form in which each connection base is divided into a plurality of ends is integrally processed adjacent to each coil connection part (a), and each connection line is Each of the divided pieces provided at the tip of the connecting line of a plurality of commutator pieces that are curved and belong to the same commutator group are connected in an annular shape so that the center of the commutator piece base is substantially coincident with the center. (B) step of configuring each of the connection bases, (c) step of molding and integrating the commutator piece base body, the plurality of connection base bodies, and the plurality of connection lines with a resin, respectively, and the annular shape The commutator piece base is divided into a plurality of commutator pieces ( ) Step, is characterized in that it has the steps of.
[0007]
A commutator comprising a plurality of commutator groups each having a plurality of commutator pieces electrically connected to a commutator body made of resin and having an insertion hole for inserting a shaft of a motor. a plurality of Rutotomoni plurality of slip rings of commutator segments arranged in the same plane of the end face of the commutator body about an axis concentrically in the hole in the same plane, a plurality of belonging to the same commutator group The commutator piece is electrically connected to a common slip ring.
[0008]
In the method of the commutator, the inside of the commutator segment base annular be divided into a plurality of commutator segments, and said plurality of slip rings about the axis of the commutator segments substrate concentrically The step (a) of arranging on the same plane including the commutator piece base, and the common commutator piece base portion to be a plurality of electrically connected commutator pieces and the common slip ring are respectively connected by connection lines. (B) step, and the commutator piece base, the plurality of slip rings, and the plurality of connection lines are respectively molded by resin so that the commutator pieces and the plurality of slip rings are integrated on the same plane of the end face of the commutator body. (C) process and (d) process which divides | segments the said annular | circular shaped commutator piece base | substrate into several commutator piece, It is characterized by the above-mentioned.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a commutator 1 according to a first embodiment of the present invention includes a disc-like or cylindrical commutator body 5 made of a resin having an insertion hole 3 for inserting a shaft of a motor. The configuration includes a plurality of commutator groups 7, 9, 11 including a plurality of electrically connected commutator pieces 7 A, 7 B, 7 C and 9 A, 9 B, 9 C and 11 A, 11 B, 11 C. The commutator pieces 7A to 7C: 9A to 9C: 11A to 11C in the commutator groups 7, 9, and 11 are each provided with a coil connecting portion 13 that is appropriately curved.
[0010]
In the commutator body 5 of the commutator 1, a plurality of commutator pieces 7A to 7C: 9A to 9C: 11A to 11C belonging to the same commutator group 7, 9, and 11 are connected. 17 and 19 (see FIG. 2) are provided.
[0011]
More specifically, when the commutator 1 is manufactured, first, as shown in FIG. 2, the portions to be divided into the plurality of commutator pieces 7A to 7C: 9A to 9C: 11A to 11C are continuous. The annular commutator piece base 21 provided with the linear coil connecting portion 13 before being bent corresponding to each of the portions to be divided is punched from a metal plate by pressing. Further, each of the annular connection bases 15, 17, 19 provided with a plurality of connection lines 23 extending in the radial direction at equal intervals in the circumferential direction is punched from a metal plate by pressing.
[0012]
Next, in the axial positional relationship of the commutator piece base 21, the axial center of the connection base 19 that is closest to the commutator piece base 21 substantially coincides with the axis of the commutator piece base 21. The plurality of connection lines 23 provided in the connection base 19 are appropriately curved to connect the distal end portion to the commutator piece base 21, and the commutator pieces 11 </ b> A and 11 </ b> B of the commutator piece base 21 are positioned. , 11C is fixed to the end portion by connecting means such as spot welding.
[0013]
Similarly, the connection bases 17 and 15 are positioned so that the axial centers of the connection bases 17 and 15 substantially coincide with the axial center of the commutator piece base 21, and the connection bases 19, 17 and 15 are spaced apart in the axial direction. In addition, the tip ends of the connection wires 23 provided in the connection bases 17 and 15 are integrated with the portions of the commutator piece base 21 that become the commutator pieces 9A, 9B, and 9C: 7A, 7B, and 7C by spot welding or the like. Secure to. At this time, the connection bases 15, 17, 19 and the plurality of connection lines 23 provided in the connection bases 15, 17, 19 are in a separated state without contacting each other.
[0014]
As described above, a plurality of electrically connected commutator pieces 7A to 7C: 9A to 9C: portions to be 11A to 11C and common connection bases 15, 17, and 19 are connected to each other through a plurality of connection lines 23, respectively. When the coil connection portion 13 is in a state of being integrally fixed and combined (the state shown in FIG. 2), the coil connection portion 13 is bent. Thereafter, the commutator piece base 21, the plurality of connection bases 15, 17, 19 and the plurality of connection lines 23 are positioned as they are in a mold (not shown), and are molded integrally with a mold resin, thereby The connection bases 17, 19, 21 and the plurality of connection lines 23 are buried (embedded) in the resin. The bending process of the coil connecting portion 13 may be after molding.
[0015]
Thereafter, the slit 25 is processed in the commutator piece base 21 to be divided into a plurality of commutator pieces 7A to 7B: 9A to 9C: 11A to 11B, and finished in the same manner as a normal commutator, A commutator 1 as shown in FIG. 1 is obtained.
[0016]
By the way, in the commutator 1 shown in FIG. 1, although illustrated about the case where several commutator piece 7A-7C: 9A-9C: 11A-11C was provided in the end surface of the commutator main body 5 shape | molded in disk shape, The commutator piece may be provided on the circumferential surface of the commutator body 5.
[0017]
FIG. 3 shows a second example when the commutator 1 is manufactured. In the configuration shown in FIG. 3, when the commutator piece base 21 is punched, a split piece 15A in which the connection bases 15, 17, 19 are divided into a plurality of pieces (the divided pieces 17A, 19A are not shown) is provided at the tip. A connecting wire 23 </ b> A (corresponding to the connecting wire 23) provided in the portion is integrally punched adjacent to the coil connecting portion 13.
[0018]
Thereafter, each connecting line 23A is appropriately bent in the direction of arrow A, and connecting lines 23A integrated with the respective commutator pieces 7A to 7C: 9A to 9C: 11A to 11C belonging to the same commutator group 7, 9, 11. The divided pieces 15A provided at the tip of each of the divided pieces 15A are connected in an annular shape so that the center of the commutator piece base 21 is substantially coincident with the center, and the connecting portions of the divided pieces 15A are integrated by spot welding or the like. By connecting to, a configuration similar to the configuration shown in FIG. 2 is obtained.
[0019]
In this second example, the commutator piece base 21, the coil connection part 13, the parts of the connection bases 15, 17, 19 and the part of the connection line 23 can be simultaneously punched from the metal plate by pressing, It is possible to improve the yield and the machining efficiency.
[0020]
FIG. 4 shows a commutator 27 according to a second embodiment of the present invention. The commutator 27 includes a disk-shaped commutator body 31 made of resin and having an insertion hole 29 for inserting the shaft of the motor. The commutator body 31 includes a plurality of electrically connected commutators 27. The commutator pieces 33A, 33B, 33C: 35A, 35B, and 35C: 37A, 37B, 37C, are provided with a plurality of commutator groups 33, 35, 37. The commutator pieces 33A to 33C: 35A to 35C: 37A to 37C in the commutator groups 33, 35, and 37 are respectively provided with coil connection portions 39 that are appropriately curved. The coil connecting portion 39 may be omitted depending on the configuration of the winding circuit in the motor.
[0021]
A plurality of slip rings 41, 43, 45 having different diameters arranged concentrically around the axial center of the insertion hole 29 are embedded in one end face of the commutator body 31. The plurality of commutator pieces are arranged outside the slip rings 41, 43, 45.
[0022]
The plurality of commutator pieces 33 </ b> A to 33 </ b> C belonging to the commutator group 33 are electrically connected to the slip ring 41. Similarly, a plurality of commutator pieces 35A to 35B: 37A to 37C belonging to the commutator groups 35 and 37 are electrically connected to the slip rings 43 and 45, respectively.
[0023]
In order to manufacture the commutator 27, a straight coil connection portion 39 before being bent is prepared while a portion to be divided into the plurality of commutator pieces 33 </ b> A to 33 </ b> C: 35 </ b> A to 35 </ b> C: 37 </ b> A to 37 </ b> C is provided in a continuous state. The annular commutator piece base body 47 (see FIG. 5) and the plurality of slip rings 41, 43, 45, which are prepared in a state of extending in the radial direction, are connected to each other by a plurality of bridges (not shown) by pressing. Punching from a metal plate.
[0024]
Thereafter, as shown in FIG. 5, the portions of the commutator group 33 that become the commutator pieces 33A, 33B, and 33C and the slip ring 41 are integrally connected by a plurality of connection lines 49A. Similarly, the commutator pieces 35A to 35C of the commutator groups 35 and 37 are connected to the slip rings 43 and 45 individually by a plurality of connection lines 49B and 49C, respectively. At this time, the connection lines 49A, 49B, and 49C are separated from each other so as not to come into contact with other slip rings and other connection lines.
[0025]
As described above, the commutator pieces 33A to 33C: 35A to 35C: 37A to 37C of the commutator groups 33, 35, and 37 are connected to the slip rings 41, 43, and 45 by the connection lines 49A, 49B, and 49C. Then, after the slip rings 41, 43, 45 are individually supported by the connection lines 49A, 49B, 49C, the commutator body 47 and the slip rings 41, 43, 45 are integrally formed. The bridge in the connected and combined state is cut.
[0026]
Thereafter, the coil connecting portion 39 provided in each of the commutator pieces 33A to 33C: 35A to 35C: 37A to 37C is appropriately curved and the commutator piece base body 47, the plurality of slip rings 41, 43, 45, and the plurality of pieces. The connecting wires 49A, 49B, and 49C are positioned in a mold (not shown), and are integrally molded with a mold resin so as to be integrally fixed.
[0027]
After molding, the commutator segments substrate 47 a plurality of commutator segments and processing the slit 51 to 33A to 33C: 35A to 35C: by splitting into 37A to 37C, as shown in FIG. 4, a plurality of The commutator 27 in which the slip rings 41, 43, 45 and the commutator pieces 33A to 33C: 35A to 35C: 37A to 37C are arranged on the same plane of the end face of the commutator body 31 is obtained.
[0028]
In this commutator 27, each of the slip rings 41, 43, 45 and commutator pieces 33A to 33C: 35A to 35C: 37A to 37C can be arranged in substantially the same plane, and the overall configuration can be made thinner. It is.
[0029]
【The invention's effect】
As can be understood from the above description, according to the present invention, a plurality of commutator pieces belonging to the same commutator group can be easily connected to the connection base and the slip ring, and the manufacture is easy. At the same time, by molding with a mold resin, the entire configuration can be embedded integrally in the mold resin, and it is easy to integrally fix it, which can solve the conventional problems as described above. .
[Brief description of the drawings]
FIG. 1 is an explanatory perspective view of a commutator according to a first embodiment of the present invention.
FIG. 2 is a perspective explanatory view showing a first example of a manufacturing method of the commutator.
FIG. 3 is an explanatory perspective view showing a second example of the method of manufacturing the commutator.
FIG. 4 is a perspective explanatory view of a commutator according to a second embodiment of the present invention.
FIG. 5 is a perspective explanatory view of a commutator manufacturing method according to a second embodiment of the present invention.
[Explanation of symbols]
1, 27 Commutator 3, 29 Insertion hole 5, 31 Commutator body 7, 9, 11, 33, 35, 37 Commutator groups 7A, 7B, 7C: 9A, 9B, 9C: 11A, 11B, 11C: 33A, 33B, 33C: 35A, 35B, 35C: 37A, 37B, 37C Commutator piece 15, 17, 19 Connection base 21, 47 Commutator piece base 25, 51 Slit 41, 43, 45 Slip ring

Claims (4)

A commutator body made of resin provided with an insertion hole for inserting the motor shaft, a plurality of commutator group consisting comprises a plurality of commutator segments which are electrically connected, spaced in the axial direction of the insertion hole In the commutator in which a plurality of connection bases are provided in the commutator body, and a plurality of commutator pieces belonging to the same commutator group are electrically connected to a common connection base .
When each of the plurality of commutator pieces is provided in a continuous state and an annular commutator piece base having a coil connection portion corresponding to each of the parts to be divided is punched, the respective connections A connecting wire having a split piece in a state where the base is divided into a plurality of ends is integrally processed adjacent to each coil connecting portion, and each connecting wire is bent to belong to the same commutator group. Each of the connection bases is configured by connecting each of the divided pieces provided at the tip of the connection line of the commutator pieces in an annular shape so that the center of the commutator piece base is substantially coincident with the center. Characteristic commutator. In the method of manufacturing a commutator,
(A) When a plurality of commutator pieces are provided in a continuous state and a circular commutator piece base provided with a coil connection portion corresponding to each of the parts to be divided is punched, A step of integrally processing a connecting wire provided at a tip portion with a divided piece in a form in which a connecting base is divided into a plurality of pieces, adjacent to each coil connecting portion ;
(B) The respective split pieces provided at the tip ends of the connection lines of a plurality of commutator pieces belonging to the same commutator group by curving each connection line are substantially coincident with the axis of the commutator piece base. A step of configuring each of the connection bases by connecting them in a ring shape ,
(C) The step of integrating the commutator piece base, the plurality of connection bases and the plurality of connection lines by molding with a resin, respectively,
(D) dividing the annular commutator piece base into a plurality of commutator pieces;
A method of manufacturing a commutator comprising the steps of: In a commutator comprising a plurality of commutator groups comprising a plurality of commutator pieces electrically connected to a commutator body made of resin and having an insertion hole for inserting the shaft of the motor, the insertion hole said commutator Rutotomoni plurality of commutator segments provided with a plurality of slip rings which are arranged concentrically on the same plane of the end face of the body about an axis provided in the same plane, a plurality of rectifying belonging to the same commutator group A commutator comprising a child piece electrically connected to a common slip ring. In the method of manufacturing a commutator,
(A) Inside the annular commutator piece base to be divided into a plurality of commutator pieces, a plurality of slip rings are concentrically formed around the axis of the commutator piece base and the commutator piece base is included. A process of arranging on the same plane ,
(B) a step of connecting each of the commutator piece base portions to be a plurality of electrically connected commutator pieces and the common slip ring by a connection line;
(C) The commutator piece base, the plurality of slip rings, and the plurality of connection lines are molded with resin, and the commutator pieces and the plurality of slip rings are integrated on the same plane of the end face of the commutator body ,
(D) dividing the annular commutator piece base into a plurality of commutator pieces;
A method of manufacturing a commutator comprising the steps of:

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