JP4308999B2

JP4308999B2 - Rotor and method for manufacturing the same

Info

Publication number: JP4308999B2
Application number: JP32421499A
Authority: JP
Inventors: 正明清水
Original assignee: Asmo Co Ltd
Current assignee: Asmo Co Ltd
Priority date: 1999-11-15
Filing date: 1999-11-15
Publication date: 2009-08-05
Anticipated expiration: 2019-11-15
Also published as: JP2001145288A

Description

【０００１】
【発明の属する技術分野】
本発明は、モータの回転子に係り、詳しくは各コイルが星形結線される回転子、及びその製造方法に関するものである。
【０００２】
【従来の技術】
従来のモータの回転子としては、回転軸に固定されたコア（鉄心）から放射状に延びる複数のティース片に巻着される各コイルを星形結線したものがある。即ち、各コイルの一端部がそれぞれ整流子ライザに結線され、各コイルの他端部がはんだ付け又は溶接により結線され、その点が中性点とされたものがある。
【０００３】
このような回転子の製造方法としては、特開平８−２９４２５３号公報に開示された方法がある。この方法は、まず３本の導線の端部をはんだ付け又は溶接により結線して中性点を形成する。そして、その中性点付近の導線が保持されるように、詳述するとティース片上に中性点付近の導線を置き、その上から中性点から離れた導線を巻着して、中性点付近の導線をティース片に縛り付ける。そして、その巻着した３本の導線の各端部をそれぞれ整流子ライザに結線する。
【０００４】
この方法では、コアとの関わりがない状態で３本の導線の端部を結線して中性点を形成することができるため、各導線を各ティース片に巻着した後にその端部を結線し中性点を形成するのに比べて、その作業が容易である。また、中性点付近の導線とティース片を縛り付けるように巻着するため、中性点を保持するために特別な部材や製造工程（最後に樹脂で接着する等）を必要としない。
【０００５】
【発明が解決しようとする課題】
ところで、上記方法では、はんだ付け時、又は溶接時の熱により中性点付近の導線の被膜が破壊されてしまうことがある。従って、中性点付近の導線とティース片を縛り付けるように巻着していく際の摩擦等により巻着する側の導線の被膜が剥れると、中性点付近の導線と中性点から離れた導線とが短絡する虞がある。これにより回転子の歩溜りが低下してしまうという問題がある。
【０００６】
本発明は上記問題点を解消するためになされたものであって、星形結線を備えた回転子及びその製造方法において、その中性点を容易に形成することができ、且つ巻線の短絡を防止することができる回転子及びその製造方法を提供することにある。
【０００７】
【課題を解決するための手段】
請求項１に記載の発明は、複数の導線が星形結線され、その中性点から離れた導線が、中性点付近の導線の上からコアに巻着されてコイルが形成される回転子において、前記コアには、前記中性点付近の導線を狭持する一対の凸部と、該凸部より前記コアの径方向内側に形成され少なくとも前記中性点付近の導線を収容するための絶縁性の収容部とが設けられ、前記コイルは、前記収容部に収容された前記中性点付近の導線の上から前記中性点から離れた導線が巻着されて形成されており、前記収容部は、該収容部に収容された前記中性点付近の導線と、該中性点付近の導線の上から巻着された前記中性点から離れた導線とが接触しないよう構成されたことを要旨とする。
【０００８】
請求項２に記載の発明は、請求項１に記載の回転子において、前記コアには、前記導線を巻着するための放射状に延びる複数のティース片が形成され、該コアの軸線方向端面には該コアの金属部と前記導線とを絶縁するための絶縁部が設けられ、前記収容部を、前記絶縁部に前記ティース片と同方向に延びるように形成したことを要旨とする。
【０００９】
請求項３に記載の発明は、請求項２に記載の回転子において、前記収容部は、前記絶縁部に形成された溝であり、前記中性点から離れた導線は、前記凸部より前記コアの径方向内側に巻着され前記コイルを形成することを要旨とする。
【００１０】
請求項４に記載の発明は、請求項２又は３に記載の回転子において、前記収容部を、前記各ティース片の前記絶縁部にそれぞれ形成し、その複数の収容部の一つに前記中性点付近の導線を収容したことを要旨とする。
【００１１】
請求項５に記載の発明は、コアには、複数の導線が星形結線された中性点付近の導線を狭持する一対の凸部と、該凸部より前記コアの径方向内側に形成され少なくとも前記中性点付近の導線を収容するための絶縁性の収容部とが設けられ、コイルは、前記収容部に収容された前記中性点付近の導線の上から前記中性点から離れた導線が巻着されて形成されており、前記収容部は、該収容部に収容された前記中性点付近の導線と、該中性点付近の導線の上から巻着された前記中性点から離れた導線とが接触しないよう構成された回転子の製造方法において、前記中性点付近の導線を前記収容部に収容した後、前記中性点から離れた導線を前記収容部に収容された前記中性点付近の導線の上から巻着して前記コイルを形成することを要旨とする。
【００１２】
請求項６に記載の発明は、請求項５に記載の回転子の製造方法において、前記コアには、前記導線を巻着するための放射状に延びる複数のティース片が形成され、該コアの軸線方向端面には該コアの金属部と前記導線とを絶縁するための絶縁部が設けられ、前記中性点付近の導線を、前記ティース片と同方向に延びるように前記絶縁部に形成された前記収容部より前記コアの径方向外側に形成された一対の凸部に狭持させ、前記凸部から続く中性点付近の導線を前記収容部内に収容し、前記中性点から離れた導線を前記凸部より径方向内側に巻着して前記コイルを形成することを要旨とする。
【００１３】
請求項１に記載の発明によれば、中性点付近の導線は、コアに設けられた絶縁性の収容部に収容され、その上から中性点から離れた導線がコアに巻着されてコイルが形成される。これにより、中性点付近の導線と、中性点から離れた導線とが接触しない。よって、中性点の形成時に中性点付近の導線の被膜が破壊されても、巻線の短絡が防止される。
【００１４】
請求項２に記載の発明によれば、コアには、導線を巻着するための放射状に延びる複数のティース片が形成され、該コアの軸線方向端面には該コアの金属部と前記導線とを絶縁するための絶縁部が設けられる。そして、中性点付近の導線は、前記絶縁部に前記ティース片と同方向に延びるように形成される収容部に収容され、その上から中性点から離れた導線がコアに巻着されてコイルが形成される。
【００１５】
請求項３に記載の発明によれば、中性点付近の導線は一対の凸部に狭持され、その凸部から続く中性点付近の導線は収容部としての溝内に収容される。そして、中性点から離れた導線は凸部より前記コアの径方向内側に巻着され、前記コイルが形成される。
【００１６】
請求項４に記載の発明によれば、前記収容部は、前記各ティース片の前記絶縁部にそれぞれ形成される。よって、回転子のバランスが良好となる。そして、その複数の収容部の一つに中性点付近の導線が収容される。
【００１７】
請求項５に記載の発明によれば、中性点付近の導線が絶縁性の収容部に収容された後、中性点から離れた導線が収容部（コア）に巻着されてコイルが形成される。これにより、中性点付近の導線と、中性点から離れた導線とが接触しない。よって、中性点の形成時に中性点付近の導線の被膜が破壊されても、巻線の短絡が防止される。
【００１８】
請求項６に記載の発明によれば、前記中性点付近の導線が凸部に狭持され、その凸部から続く中性点付近の導線が収容部内に収容される。そして、中性点から離れた導線が凸部よりコアの径方向内側に巻着されてコイルが形成される。
【００１９】
【発明の実施の形態】
以下、本発明を具体化した一実施形態を図１〜図７に従って説明する。
図１は、直流モータの回転子（電機子）の側面図である。回転子は、回転軸１、コア２、整流子３及びコイル４を備える。回転軸１の中間部にはコア２が固定され、回転軸１の一端側には整流子３が固定されている。
【００２０】
図２は、コイル４が形成される前の状態の回転子の斜視図である。図３は、コイル４が形成される前の状態の回転子の概略正面図である。図４は、コイル４が形成される前の状態の回転子の概略縦断面図である。コア２は、複数のコアシート５を重合させた積層鋼板から構成される金属部６と、金属部６とコイル４とを絶縁するための樹脂よりなる絶縁部７とを備える。
【００２１】
金属部６は、回転軸１を内嵌する円筒部８ａと、円筒部８ａから等角度（１２０°）間隔に放射状に延びる３個の金属ティース片８ｂとを備える。金属ティース片８ｂの先端部には、回転軸１の周方向に延びる延出部８ｃが形成されている。
【００２２】
絶縁部７は、金属部６の軸線方向端面をそれぞれ略覆うように形成された第１及び第２絶縁端部７ａ，７ｂと、延出部８ｃの外周側を除き両絶縁端部７ａ，７ｂを軸線方向に連結するスロット絶縁部７ｃと、各絶縁端部７ａ，７ｂから軸線方向に延び回転軸１を内嵌する第１及び第２円筒部７ｄ，７ｅとを備える。本実施の形態では、金属ティース片８ｂとそれを覆うスロット絶縁部７ｃがティース片９を構成している。
【００２３】
第１円筒部７ｄには、整流子３を固定する薄肉部７ｆが形成されている。
第２絶縁端部７ｂには、一対の第１凸部１０と一対の第２凸部１１が各ティース片９毎、即ち３組づつ形成されている。
【００２４】
第２凸部１１は、第２絶縁端部７ｂの径方向外側に、各ティース片９の先端部と対応して形成されている。第２凸部１１の高さは、ティース片９に巻着されるコイル４がコア２の径方向外側に飛び出さないように設定されている（図７参照）。一対の第２凸部１１は、その対向する面が傾斜され、両凸部間に略Ｖ字形状のＶ字溝１１ａを形成する。このＶ字溝１１ａの幅は、底に向かうほど狭くなり、底での幅は３本の導線を束ねた径より若干小さく設定されている。又、第２凸部１１の一方には、図３に示すように、Ｖ字溝１１ａの幅をコア２の中心軸に向かうほど広くするテーパ面１１ｂが形成されている。このテーパ面１１ｂにより決定されるＶ字溝１１ａのコア２の径方向内側での幅は、３本の導線を束ねた径より若干広く設定されている。
【００２５】
第１凸部１０は、第２絶縁端部７ｂの第２凸部１１より径方向内側に、各ティース片９と同方向に（放射状に）延びて形成されている。この第１凸部１０は、第２凸部１１から第２円筒部７ｅの近傍まで形成されている。第１凸部１０の高さは、第２凸部１１より低く、３本の導線を束ねた径より高く設定されている。又、第１凸部１０の径方向外側端部には径方向外側に向かうほど高さが高くなる高凸部としての傾斜部１０ａが形成されている（図７参照）。一対の第１凸部１０は、その両凸部間に略Ｕ字形状の収容部としてのＵ字溝１０ｂを形成する。このＵ字溝１０ｂの幅は、３本の導線を束ねた径より広く設定されている。
【００２６】
第１絶縁端部７ａには、前記第２凸部１１と同形状の整流子側凸部１２が同様に形成されている。
コイル４は、各ティース片９に導線１３を巻着して形成され、図５に示すように、その一端から延びる導線１３が星形結線（Ｙ結線）され、中性点１４が形成されている。又、中性点１４付近の導線１３は撚られて（ねじって束ねられて）ツイスト部１５が形成されている。
【００２７】
ツイスト部１５の中性点１４側は、図５及び図７に示すように、１組の第２凸部１１のＶ字溝１１ａの底付近で第２凸部１１に狭持されている。そして、ツイスト部１５は第１凸部１０のＵ字溝１０ｂ内に収容されている。そして、ツイスト部１５から分岐した（中性点１４から離れた）各導線１３は、それぞれ第２凸部１１より径方向内側のティース片９に巻着されてコイル４を形成している。
【００２８】
ここで、中性点１４が保持されたティース片９に形成されるコイル４は、図６及び図７に示すように、Ｕ字溝１０ｂ内に収容されたツイスト部１５の上から導線１３が巻着されて形成されている。
【００２９】
各コイル４の他端から延びる導線１３は、図１に示すように、整流子３のライザ３ａに固定されている。
上記のように構成される回転子の製造方法を以下に記載する。
【００３０】
まず３本の導線１３の一端部を撚ってツイスト部１５を形成し、その先端をはんだ付け又は溶接により結線して中性点１４を形成する。
次に、ツイスト部１５の中性点１４側を、図５及び図７に示すように、１組の第２凸部１１のＶ字溝１１ａの底付近まで押しこみ、第２凸部１１に狭持させる。
【００３１】
次に、ツイスト部１５を第１凸部１０のＵ字溝１０ｂ内に収容させる。
次に、ツイスト部１５から分岐した（中性点１４から離れた）各導線１３を、それぞれ第２凸部１１より径方向内側のティース片９に巻着してコイル４を形成する。このとき、中性点１４が保持されたティース片９には、図６及び図７に示すように、Ｕ字溝１０ｂ内に収容されたツイスト部１５の上から導線１３を巻着してコイル４を形成する。
【００３２】
次に、各コイル４の他端から延びる導線１３を、図１に示すように、整流子３のライザ３ａに固定する。
上記実施の形態の効果を以下に記載する。
【００３３】
（１）ツイスト部１５は、第１凸部１０のＵ字溝１０ｂ内に収容され、その上からツイスト部１５から分岐した導線１３がティース片９に巻着されてコイル４が形成されている。これにより、ツイスト部１５と、ツイスト部１５から分岐した導線１３とが接触しない。よって、中性点１４の形成時にツイスト部１５の被膜が破壊されても、ツイスト部１５とコイル４が短絡することは防止される。
【００３４】
（２）収容部としてのＵ字溝１０ｂは、絶縁部７に一体形成されるため、容易に形成される。
（３）一対の第２凸部１１はＶ字溝１１ａを形成し、ツイスト部１５の中性点１４側はＶ字溝１１ａの底付近で第２凸部１１に狭持される。しかも、この第２凸部１１は第１凸部１０より高く形成され、導線１３は第２凸部１１より径方向内側のティース片９に巻着されてコイル４を形成するため、コイル４がコア２の径方向外側に飛び出すことは第２凸部１１により防止される。即ち、第２凸部１１は、中性点１４を保持する機能と、コイル４がコア２の径方向外側に飛び出すことを防止する機能とを兼ね備える。よって、絶縁部７の形状が簡略化される。
【００３５】
（４）中性点１４は、第２凸部１１より径方向外側に配置され、コイル４は第２凸部１１より径方向内側に配置される。よって、被膜の無い中性点１４とコイル４とが接触することは防止され、中性点１４とコイル４が短絡することはない。
【００３６】
（５）第１凸部１０の径方向外側端部には第２凸部１１に向かうほど高さが高くなる傾斜部１０ａを形成した。これにより、第１凸部１０の径方向外側端部の高さが高くなり、第１凸部の径方向内側の高さが低くなる。よって、導線１３が巻着されるスペースを広く確保しながら、Ｖ字溝１１ａの底付近で狭持されたツイスト部１５がＵ字溝１０ｂの底に接触するまでの間に底から浮いた状態となっても、傾斜部１０ａによりＵ字溝１０ｂ内に収容させることができる。しかも、Ｖ字溝１１ａに近い部分は、中性点１４の形成時に被膜が破壊される確立が高いが、傾斜部１０ａによりコイル４と確実に非接触とされる。よって、ツイスト部１５とコイル４が短絡することは防止される。
【００３７】
（６）第１及び第２凸部１０，１１は、各ティース片９と対応した位置にそれぞれ形成されるため、回転子のバランスが良好となる。よって、回転トルクのムラ等が低減される。
【００３８】
（７）コア２との関わりがない状態で３本の導線１３の一端部を結線して中性点１４を形成することができるため、各導線を各ティース片に巻着した後にその端部を結線し中性点を形成するのに比べて、その作業が容易となる。
【００３９】
上記実施の形態は、以下のように変更して実施してもよい。
・上記実施の形態では、ツイスト部１５（中性点１４付近の導線）を収容するためにＵ字溝１０ｂ（収容部）を形成する一対の第１凸部１０を設けたが、少なくともツイスト部１５を収容可能であれば、詳述するとツイスト部１５を収容した上から導線１３を巻着してもツイスト部１５と導線１３とが接触しなければ、Ｕ字溝１０ｂを他の構成としてもよい。例えば、絶縁部７に溝を凹設し、その溝を収容部としてもよい。このようにしても、ツイスト部１５（中性点１４付近の導線）とコイル４が短絡することは防止される。又、例えば、第１凸部１０を第２凸部１１より径方向外側まで形成し、中性点１４をも収容するものとしてもよい。
【００４０】
・上記実施の形態では、第１凸部１０を絶縁部７に一体形成したが、絶縁性の別部材で構成してもよい。このようにしても上記実施の形態の効果（１），（３）〜（７）と同様の効果を得ることができる。
【００４１】
・上記実施の形態では、第２凸部１１は、Ｖ字溝１１ａを形成し、第１凸部１０より高く形成され、中性点１４を保持する機能と、コイル４がコア２の径方向外側に飛び出すことを防止する機能とを兼ね備えるとしたが、機能毎に別に構成してもよい。このようにしても上記実施の形態の効果（１），（２），（６），（７）と同様の効果を得ることができる。
【００４２】
・上記実施の形態では、第１凸部１０の径方向外側端部に傾斜部１０ａを形成したが、傾斜部１０ａを設けなくてもよい。このようにしても上記実施の形態の効果（１）〜（４），（６），（７）と同様の効果を得ることができる。
【００４３】
・上記実施の形態では、第１及び第２凸部１０，１１は、各ティース片９と対応した位置にそれぞれ形成されるとしたが、一つのティース片９に一対のみ設けてもよい。このようにしても、上記実施の形態の効果（１）〜（６），（７）と同様の効果を得ることができる。
【００４４】
・上記実施の形態では、中性点１４付近の導線は撚られてツイスト部１５とされているとしたが、撚られていなくてもよい。
・上記実施の形態では、３つのコイル４がＹ結線される回転子に具体化したが、多数（例えば６つ）のコイルが星形結線される回転子に具体化してもよい。
【００４５】
上記各実施の形態から把握できる技術的思想について、以下にその効果とともに記載する。
（イ）請求項１に記載の回転子において、前記収容部を、前記コア表面に設けられ該コアの金属部と前記導線とを絶縁するための絶縁部に形成したことを特徴とする回転子。
【００４６】
このようにすると、絶縁性の収容部は、コアの金属部と導線とを絶縁するための絶縁部に一体形成されるため、容易に成形される。
（ロ）前記収容部は、前記絶縁部に凸設された一対の第１凸部が形成する溝であり、前記第１凸部より前記コアの径方向外側には、前記中性点付近の導線を狭持する一対の第２凸部を設けたことを特徴とする。
【００４７】
このようにすると、中性点付近の導線は一対の第２凸部に狭持され、その第２凸部から続く中性点付近の導線は一対の第１凸部が形成する溝内に収容される。そして、中性点から離れた導線は、その上からコアに巻着される。
【００４８】
（ハ）前記一対の第２凸部は、樹脂製でその間に略Ｖ字形状のＶ字溝を形成し、そのＶ字溝の底の幅は、前記複数の導線の束ねられた径より若干小さいことを特徴とする。このようにすると、中性点付近の導線の中性点側の部分は、Ｖ字溝の底付近で狭持される。
【００４９】
（ニ）上記（ハ）に記載の回転子において、前記第１凸部の径方向外側端部には、高さの高い高凸部（１０ａ）を形成したことを特徴とする回転子。
このようにすると、第１凸部の径方向外側端部の高さが高くなり、第１凸部の径方向外側端部以外の高さが低くなる。よって、導線が巻着されるスペースを広く確保しながら、Ｖ字溝の底付近で狭持された中性点付近の導線が第１凸部が形成する溝の底に接触するまでの間に底から浮いた状態となっても、高凸部により第１凸部の溝内に収容させることができる。
【００５０】
【発明の効果】
以上、詳述したように、請求項１〜４に記載の発明によれば、星形結線を備えた回転子において、その中性点を容易に形成することができ、且つ巻線の短絡を防止することができる回転子を提供することができる。
請求項５，６に記載の発明によれば、星形結線を備えた回転子の製造方法において、その中性点を容易に形成することができ、且つ巻線の短絡を防止することができる回転子の製造方法を提供することができる。
【図面の簡単な説明】
【図１】本実施の形態の回転子の側面図。
【図２】コイルが形成される前の状態の回転子の斜視図。
【図３】コイルが形成される前の状態の回転子の概略正面図。
【図４】コイルが形成される前の状態の回転子の概略縦断面図。
【図５】本実施の形態の回転子を説明するための説明図。
【図６】図５のＡ−Ａ断面図。
【図７】本実施の形態の回転子を説明するための要部概略断面図。
【符号の説明】
１…コア、４…コイル、６…金属部、７…絶縁部、９…ティース片、１０…第１凸部、１１…第２凸部、１３…導線、１４…中性点、１５…ツイスト部、１０ｂ…Ｕ字溝。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a rotor of a motor, and more particularly to a rotor in which each coil is star-connected and a method for manufacturing the same.
[0002]
[Prior art]
As a conventional motor rotor, there is one in which each coil wound around a plurality of teeth pieces extending radially from a core (iron core) fixed to a rotating shaft is star-connected. That is, one end of each coil is connected to a commutator riser, the other end of each coil is connected by soldering or welding, and that point is a neutral point.
[0003]
As a method for manufacturing such a rotor, there is a method disclosed in JP-A-8-294253. In this method, first, the ends of the three conductors are connected by soldering or welding to form a neutral point. Then, in detail, place the conductive wire near the neutral point on the teeth piece so that the conductive wire near the neutral point is held, wind the conductive wire away from the neutral point from above the neutral point, Tie a nearby conductor to a piece of teeth. And each end part of the wound three conducting wire is each connected to a commutator riser.
[0004]
In this method, the end of the three conductors can be connected to form a neutral point in a state where there is no connection with the core, so that the ends are connected after each conductor is wound around each tooth piece. However, the operation is easier than forming neutral points. Moreover, since it winds so that the conducting wire and teeth piece near a neutral point may be tied, a special member and a manufacturing process (final adhesion | attachment with resin etc.) are not required in order to hold | maintain a neutral point.
[0005]
[Problems to be solved by the invention]
By the way, in the said method, the film of the conducting wire near a neutral point may be destroyed by the heat at the time of soldering or welding. Therefore, if the coated wire on the winding side is peeled off due to friction or the like when winding so as to tie the conductive wire near the neutral point and the tooth piece, the conductive wire near the neutral point and the neutral point will be separated. There is a risk of short circuiting with the lead wires. As a result, there is a problem that the yield of the rotor decreases.
[0006]
The present invention has been made to solve the above-described problems, and in a rotor having a star connection and a manufacturing method thereof, the neutral point can be easily formed, and a short circuit of a winding is achieved. An object of the present invention is to provide a rotor and a method for manufacturing the same.
[0007]
[Means for Solving the Problems]
The invention according to claim 1, a plurality of lead is star-connected, wires away from the neutral point, the coil is formed is wound around on the one Raco A conductor in the vicinity of the neutral point In the rotor, the core accommodates a pair of convex portions that sandwich the conductive wire near the neutral point, and at least a conductive wire that is formed radially inward of the core from the convex portion and near the neutral point. an insulating housing portion is provided for, it said coil conductor remote from the neutral point from the top of the conductor in the vicinity of the neutral point, which is accommodated in the accommodation portion is formed is wound around The accommodating portion is configured such that the conductor near the neutral point accommodated in the accommodating portion does not contact the conductor separated from the neutral point wound around the conductor near the neutral point. It is a summary.
[0008]
According to a second aspect of the present invention, in the rotor according to the first aspect, the core is formed with a plurality of radially extending teeth pieces for winding the conducting wire, and the axial end surface of the core is formed on the core. The gist is that an insulating part for insulating the metal part of the core and the conducting wire is provided, and the accommodating part is formed in the insulating part so as to extend in the same direction as the teeth piece.
[0009]
Invention according to claim 3, in the rotor according to claim 2, wherein the accommodating portion, the a groove formed in the insulating portion, the wire away from the front Symbol neutral point, before Kitotsu portion The gist is to form the coil by being wound more radially inside the core.
[0010]
According to a fourth aspect of the present invention, in the rotor according to the second or third aspect, the accommodating portion is formed in the insulating portion of each of the teeth pieces, and the intermediate portion is included in one of the plural accommodating portions. The gist is that the conductor near the sex point was accommodated.
[0011]
According to a fifth aspect of the present invention, the core is formed with a pair of convex portions sandwiching a conductive wire in the vicinity of a neutral point where a plurality of conductive wires are star-connected , and radially inward of the core from the convex portions. And an insulating accommodating portion for accommodating at least a conducting wire near the neutral point, and the coil is separated from the neutral point from above the conducting wire near the neutral point accommodated in the accommodating portion. conducting wire is formed is wound around the accommodating portion includes a conductor in the vicinity of the neutral point, which is accommodated in the accommodating portion, the neutral, which is wrapped over the lead in the vicinity of neutral point in the configuration process for the preparation of the rotor so as not to contact the wire away from the point, after housing the wire around the neutral point in the housing part, accommodating the wire away from the neutral point in the housing part The gist is to form the coil by winding it around the conducting wire near the neutral point .
[0012]
According to a sixth aspect of the present invention, in the method for manufacturing a rotor according to the fifth aspect, the core includes a plurality of radially extending teeth pieces for winding the conductive wire, and the axis of the core. An insulating portion for insulating the metal portion of the core and the conducting wire is provided on the end surface in the direction, and the conducting wire near the neutral point is formed in the insulating portion so as to extend in the same direction as the teeth piece. the receiving portion is interposed a pair of projections formed on the radially outer side of the core than to accommodate the conductors in the vicinity of the neutral point continued from previous Kitotsu unit in front KiOsamu Description section, from the neutral point and wrapped than the previous Kitotsu portion radially inwardly away from wires and summarized in that to form the coil.
[0013]
According to the first aspect of the present invention, the conductor near the neutral point is accommodated in the insulating accommodating portion provided in the core, and the conductor away from the neutral point from above is wound around the core. A coil is formed. Thereby, the conducting wire near the neutral point and the conducting wire away from the neutral point do not contact. Therefore, even if the coating of the conductive wire near the neutral point is broken when the neutral point is formed, a short circuit of the winding is prevented.
[0014]
According to the second aspect of the present invention, the core is formed with a plurality of radially extending teeth pieces for winding the conducting wire, and the metal end portion of the core and the conducting wire are formed on the axial end surface of the core. An insulating part is provided for insulating. And the conducting wire near the neutral point is accommodated in the accommodating portion formed to extend in the same direction as the teeth piece in the insulating portion, and the conducting wire away from the neutral point from above is wound around the core. A coil is formed.
[0015]
According to the invention described in claim 3, wires around the neutral point is sandwiched pair of convex portions, conductors near neutral continuing from the convex portion of its is accommodated in the groove of the housing part . And the conducting wire away from the neutral point is wound around the radial inside of the core from the convex portion, and the coil is formed .
[0016]
According to invention of Claim 4, the said accommodating part is each formed in the said insulation part of each said teeth piece. Therefore, the balance of the rotor is good. And the conducting wire near the neutral point is accommodated in one of the plurality of accommodating portions.
[0017]
According to the fifth aspect of the present invention, after the conducting wire in the vicinity of the neutral point is accommodated in the insulating accommodating portion, the conducting wire away from the neutral point is wound around the accommodating portion (core) to form a coil. Is done. Thereby, the conducting wire near the neutral point and the conducting wire away from the neutral point do not contact. Therefore, even if the coating of the conductive wire near the neutral point is broken when the neutral point is formed, a short circuit of the winding is prevented.
[0018]
According to the invention of claim 6, wires in the vicinity of the neutral point is sandwiched protrusion is accommodated in the conductor Scheme 13 ml portion of the vicinity of the neutral point continuing from the convex portion of it. And the conducting wire away from the neutral point is wound from the convex portion to the inside in the radial direction of the core to form a coil .
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment embodying the present invention will be described with reference to FIGS.
FIG. 1 is a side view of a rotor (armature) of a DC motor. The rotor includes a rotating shaft 1, a core 2, a commutator 3 and a coil 4. A core 2 is fixed to an intermediate portion of the rotating shaft 1, and a commutator 3 is fixed to one end side of the rotating shaft 1.
[0020]
FIG. 2 is a perspective view of the rotor in a state before the coil 4 is formed. FIG. 3 is a schematic front view of the rotor in a state before the coil 4 is formed. FIG. 4 is a schematic longitudinal sectional view of the rotor in a state before the coil 4 is formed. The core 2 includes a metal part 6 composed of a laminated steel plate obtained by polymerizing a plurality of core sheets 5, and an insulating part 7 made of a resin for insulating the metal part 6 and the coil 4.
[0021]
The metal part 6 includes a cylindrical part 8a in which the rotary shaft 1 is fitted, and three metal teeth pieces 8b that extend radially from the cylindrical part 8a at equiangular (120 °) intervals. An extension 8c extending in the circumferential direction of the rotating shaft 1 is formed at the tip of the metal tooth piece 8b.
[0022]
The insulating portion 7 includes both first and second insulating end portions 7a and 7b formed so as to substantially cover the end surfaces in the axial direction of the metal portion 6, and both insulating end portions 7a and 7b except for the outer peripheral side of the extending portion 8c. And the first and second cylindrical portions 7d and 7e extending in the axial direction from the respective insulating end portions 7a and 7b and fitting the rotary shaft 1 therein. In the present embodiment, the metal tooth piece 8 b and the slot insulating portion 7 c covering the metal tooth piece 8 b constitute the tooth piece 9.
[0023]
A thin portion 7f that fixes the commutator 3 is formed in the first cylindrical portion 7d.
A pair of first convex portions 10 and a pair of second convex portions 11 are formed on the second insulating end portion 7b for each tooth piece 9, that is, three sets.
[0024]
The 2nd convex part 11 is formed corresponding to the front-end | tip part of each teeth piece 9 in the radial direction outer side of the 2nd insulation edge part 7b. The height of the 2nd convex part 11 is set so that the coil 4 wound by the teeth piece 9 may not jump out to the radial direction outer side of the core 2 (refer FIG. 7). The pair of second convex portions 11 are inclined at opposing surfaces, and form a substantially V-shaped V-shaped groove 11a between the convex portions. The width of the V-shaped groove 11a becomes narrower toward the bottom, and the width at the bottom is set slightly smaller than the diameter of the bundle of three conducting wires. Further, as shown in FIG. 3, a tapered surface 11 b is formed on one side of the second convex portion 11 so that the width of the V-shaped groove 11 a becomes wider toward the central axis of the core 2. The width of the V-shaped groove 11a determined by the tapered surface 11b on the inner side in the radial direction of the core 2 is set to be slightly wider than the diameter of the bundle of three conducting wires.
[0025]
The 1st convex part 10 is formed in the radial direction inner side rather than the 2nd convex part 11 of the 2nd insulation edge part 7b, and is extended in the same direction as each teeth piece 9 (radially). The first convex portion 10 is formed from the second convex portion 11 to the vicinity of the second cylindrical portion 7e. The height of the 1st convex part 10 is set rather than the 2nd convex part 11, and higher than the diameter which bundled three conducting wires. Further, an inclined portion 10a as a high convex portion whose height increases toward the radially outer side is formed at the radially outer end portion of the first convex portion 10 (see FIG. 7). A pair of 1st convex part 10 forms the U-shaped groove | channel 10b as a substantially U-shaped accommodating part between the both convex parts. The width of the U-shaped groove 10b is set wider than the diameter of the three conducting wires bundled.
[0026]
A commutator-side convex portion 12 having the same shape as the second convex portion 11 is similarly formed on the first insulating end portion 7a.
The coil 4 is formed by winding a conductive wire 13 around each tooth piece 9, and as shown in FIG. 5, the conductive wire 13 extending from one end thereof is star-connected (Y-connected), and a neutral point 14 is formed. Yes. The conductive wire 13 near the neutral point 14 is twisted (twisted and bundled) to form a twisted portion 15.
[0027]
As shown in FIGS. 5 and 7, the neutral point 14 side of the twist portion 15 is held by the second convex portion 11 near the bottom of the V-shaped groove 11 a of the pair of second convex portions 11. The twist portion 15 is accommodated in the U-shaped groove 10 b of the first convex portion 10. Then, each conductive wire 13 branched from the twist portion 15 (away from the neutral point 14) is wound around a tooth piece 9 radially inward from the second convex portion 11 to form the coil 4.
[0028]
Here, as shown in FIGS. 6 and 7, the coil 4 formed on the tooth piece 9 holding the neutral point 14 has the conductor 13 from above the twist portion 15 accommodated in the U-shaped groove 10 b. It is formed by winding.
[0029]
The conducting wire 13 extending from the other end of each coil 4 is fixed to the riser 3a of the commutator 3 as shown in FIG.
A method for manufacturing the rotor configured as described above will be described below.
[0030]
First, one end of the three conducting wires 13 is twisted to form the twisted portion 15, and the tip is connected by soldering or welding to form the neutral point 14.
Next, as shown in FIGS. 5 and 7, the neutral point 14 side of the twist portion 15 is pushed into the vicinity of the bottom of the V-shaped groove 11 a of the pair of second convex portions 11, and the second convex portion 11 is pushed. Hold it.
[0031]
Next, the twist part 15 is accommodated in the U-shaped groove 10 b of the first convex part 10.
Next, each of the conductive wires 13 branched from the twist portion 15 (away from the neutral point 14) is wound around the tooth piece 9 radially inward from the second convex portion 11 to form the coil 4. At this time, as shown in FIGS. 6 and 7, a conductive wire 13 is wound around the tooth piece 9 holding the neutral point 14 from above the twist portion 15 accommodated in the U-shaped groove 10b. 4 is formed.
[0032]
Next, the conducting wire 13 extending from the other end of each coil 4 is fixed to the riser 3a of the commutator 3 as shown in FIG.
The effects of the above embodiment will be described below.
[0033]
(1) The twist part 15 is accommodated in the U-shaped groove 10b of the first convex part 10, and the conductive wire 13 branched from the twist part 15 from above is wound around the tooth piece 9 to form the coil 4. . Thereby, the twist part 15 and the conducting wire 13 branched from the twist part 15 do not contact. Therefore, even if the film of the twisted portion 15 is broken when the neutral point 14 is formed, the twisted portion 15 and the coil 4 are prevented from being short-circuited.
[0034]
(2) Since the U-shaped groove 10b as the accommodating portion is integrally formed with the insulating portion 7, it is easily formed.
(3) The pair of second convex portions 11 form a V-shaped groove 11a, and the neutral point 14 side of the twisted portion 15 is sandwiched between the second convex portions 11 near the bottom of the V-shaped groove 11a. In addition, the second convex portion 11 is formed higher than the first convex portion 10, and the conductive wire 13 is wound around the tooth piece 9 radially inward from the second convex portion 11 to form the coil 4. The second protrusion 11 prevents the core 2 from protruding outward in the radial direction. That is, the second convex portion 11 has a function of holding the neutral point 14 and a function of preventing the coil 4 from jumping out to the outside in the radial direction of the core 2. Therefore, the shape of the insulating part 7 is simplified.
[0035]
(4) The neutral point 14 is disposed on the radially outer side from the second convex portion 11, and the coil 4 is disposed on the radially inner side from the second convex portion 11. Therefore, the neutral point 14 without a coating and the coil 4 are prevented from contacting each other, and the neutral point 14 and the coil 4 are not short-circuited.
[0036]
(5) An inclined portion 10 a whose height increases toward the second convex portion 11 is formed at the radially outer end of the first convex portion 10. Thereby, the height of the radially outer end portion of the first convex portion 10 is increased, and the height of the first convex portion on the radially inner side is decreased. Thus, while ensuring a wide space around which the conductive wire 13 is wound, the twisted portion 15 held near the bottom of the V-shaped groove 11a is floating from the bottom until it comes into contact with the bottom of the U-shaped groove 10b. Even if it becomes, it can be accommodated in the U-shaped groove 10b by the inclined portion 10a. In addition, the portion close to the V-shaped groove 11a is highly likely to be destroyed when the neutral point 14 is formed, but is reliably brought into non-contact with the coil 4 by the inclined portion 10a. Therefore, a short circuit between the twist portion 15 and the coil 4 is prevented.
[0037]
(6) Since the 1st and 2nd convex parts 10 and 11 are each formed in the position corresponding to each teeth piece 9, the balance of a rotor becomes favorable. Therefore, unevenness in rotational torque and the like are reduced.
[0038]
(7) Since one end part of the three conducting wires 13 can be connected to form the neutral point 14 without being associated with the core 2, the end part after each conducting wire is wound around each tooth piece. Compared with forming a neutral point, the operation becomes easier.
[0039]
The above embodiment may be modified as follows.
In the above embodiment, the pair of first convex portions 10 that form the U-shaped groove 10b (accommodating portion) is provided to accommodate the twist portion 15 (the conducting wire near the neutral point 14), but at least the twist portion If it is possible to accommodate 15, more specifically, even if the conductive wire 13 is wound after the twisted portion 15 is accommodated, if the twisted portion 15 and the conductive wire 13 do not come into contact with each other, the U-shaped groove 10 b may have another configuration. Good. For example, a groove may be provided in the insulating portion 7 and the groove may be used as the accommodating portion. Even in this case, the twist portion 15 (the conducting wire near the neutral point 14) and the coil 4 are prevented from being short-circuited. Further, for example, the first convex portion 10 may be formed to the outside in the radial direction from the second convex portion 11, and the neutral point 14 may be accommodated.
[0040]
-In above-mentioned embodiment, although the 1st convex part 10 was integrally formed in the insulating part 7, you may comprise by another member with insulation. Even if it does in this way, the effect similar to the effect (1) of the said embodiment, (3)-(7) can be acquired.
[0041]
In the above embodiment, the second convex portion 11 forms the V-shaped groove 11 a and is formed higher than the first convex portion 10, the function of holding the neutral point 14, and the coil 4 in the radial direction of the core 2. Although it has the function of preventing it from popping outside, it may be configured separately for each function. Even if it does in this way, the effect similar to the effect (1), (2), (6), (7) of the said embodiment can be acquired.
[0042]
-In above-mentioned embodiment, although the inclination part 10a was formed in the radial direction outer side edge part of the 1st convex part 10, it is not necessary to provide the inclination part 10a. Even if it does in this way, the effect similar to effect (1)-(4), (6), (7) of the said embodiment can be acquired.
[0043]
In the above embodiment, the first and second convex portions 10 and 11 are formed at positions corresponding to the respective tooth pieces 9, but only one pair may be provided on one tooth piece 9. Even if it does in this way, the effect similar to effect (1)-(6), (7) of the said embodiment can be acquired.
[0044]
-In above-mentioned embodiment, although the conducting wire of the neutral point 14 vicinity was twisted and it was set as the twist part 15, it does not need to be twisted.
In the above-described embodiment, the three coils 4 are embodied in the rotor connected in the Y direction. However, a large number (for example, six) coils may be embodied in the rotor connected in the star shape.
[0045]
For technical ideas that can be grasped from the above embodiments will be described in conjunction with the effects below.
(A) The rotor according to claim 1, wherein the housing portion is formed on an insulating portion provided on the core surface for insulating the metal portion of the core and the conductive wire. .
[0046]
If it does in this way, since an insulating accommodating part is integrally formed in the insulation part for insulating the metal part and conducting wire of a core, it shape | molds easily.
(B) pre-Symbol accommodating portion is a groove in which the first convex portions of the pair which is projectingly on the insulating portion is formed, wherein the radially outer side of the core than the first convex portion, around the neutral point second convex portions of the pair of sandwiching the conductors you, characterized in that the provided.
[0047]
In this way, the conductive wire near the neutral point is held between the pair of second convex portions, and the conductive wire near the neutral point continuing from the second convex portion is accommodated in the groove formed by the pair of first convex portions. Is done. And the conducting wire away from the neutral point is wound around the core from above.
[0048]
(C) before Symbol second convex portions of the pair, while in resin a to form a V-shaped groove of substantially V-shape, the width of the bottom of the V-shaped groove, than the diameter bundled with the plurality of conductors it characterized in that the slightly smaller. If it does in this way, the part by the side of the neutral point of conducting wire near a neutral point will be pinched near the bottom of a V-shaped groove.
[0049]
(D) The rotor according to (c) above, wherein a high convex part (10a) having a high height is formed at a radially outer end of the first convex part.
If it does in this way, the height of the radial direction outer end part of a 1st convex part will become high, and heights other than the radial direction outer end part of a 1st convex part will become low. Therefore, while ensuring a wide space around which the conducting wire is wound, the conducting wire near the neutral point held near the bottom of the V-shaped groove contacts the bottom of the groove formed by the first convex portion. Even if it floats from the bottom, it can be accommodated in the groove of the first convex portion by the high convex portion.
[0050]
【The invention's effect】
As described above in detail, according to the invention described in claims 1 to 4, in the rotor provided with the star connection, the neutral point can be easily formed, and the short circuit of the winding can be performed. A rotor that can be prevented can be provided.
According to the fifth and sixth aspects of the invention, in the method of manufacturing a rotor having a star connection, the neutral point can be easily formed and the short circuit of the winding can be prevented. A method for manufacturing a rotor can be provided.
[Brief description of the drawings]
FIG. 1 is a side view of a rotor according to an embodiment.
FIG. 2 is a perspective view of a rotor in a state before a coil is formed.
FIG. 3 is a schematic front view of the rotor in a state before a coil is formed.
FIG. 4 is a schematic longitudinal sectional view of a rotor in a state before a coil is formed.
FIG. 5 is an explanatory diagram for explaining a rotor according to the present embodiment;
6 is a cross-sectional view taken along line AA in FIG.
FIG. 7 is a schematic cross-sectional view of a main part for explaining the rotor of the present embodiment.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Core, 4 ... Coil, 6 ... Metal part, 7 ... Insulating part, 9 ... Teeth piece, 10 ... 1st convex part, 11 ... 2nd convex part, 13 ... Conductor, 14 ... Neutral point, 15 ... Twist Part, 10b ... U-shaped groove.

Claims

A plurality of conductors (13) is star-connected, the wire away from the neutral point (14) (13) is wound around on the one Raco A conductor in the vicinity of the neutral point (15) (2) In the rotor in which the coil (4) is formed,
The core (2) includes a pair of convex portions (11) that sandwich the conductive wire (15) near the neutral point (14), and a radially inner side of the core (2) from the convex portion (11). at least the neutral point is formed (14) an insulating housing portion for housing the conductor wire (15) in the vicinity of and (10b) are provided,
The coil (4) is wound by a conductor (13) away from the neutral point (14) from above the conductor (15) in the vicinity of the neutral point (14) accommodated in the accommodating portion (10b). The accommodating portion (10b) includes a conductor (15) near the neutral point (14) accommodated in the accommodating portion (10b) and a conductor near the neutral point (14). (15) A rotor configured to prevent contact with a conducting wire (13) separated from the neutral point (14) wound from above .

The rotor according to claim 1,
The core (2) is formed with a plurality of radially extending teeth pieces (9) for winding the conducting wire (13), and the axial end surface of the core (2) is provided with the core (2). An insulating part (7) for insulating the metal part (6) and the conducting wire (13) is provided,
The rotor, wherein the accommodating portion (10b) is formed in the insulating portion (7) so as to extend in the same direction as the teeth piece (9).

The rotor according to claim 2, wherein
The accommodating part (10b) is a groove formed in the insulating part (7),
Before SL lead away from the neutral point (14) (13), and characterized in that the wrapped radially inward of the core (2) from the front Kitotsu portion (11) to form the coil (4) Rotor.

In the rotor according to claim 2 or 3,
The accommodating portion (10b) is formed in the insulating portion (7) of each of the tooth pieces (9), and a conductive wire (near the neutral point (14)) is provided in one of the plural accommodating portions (10b) ( 15) A rotor characterized by containing the same.

The core (2) includes a pair of convex portions (11) that sandwich the conductive wire (15) near the neutral point (14) in which a plurality of conductive wires (13) are star-connected, and the convex portion (11). An insulative accommodating portion (10b) that is formed on the radially inner side of the core (2) and accommodates at least the conductive wire (15) near the neutral point (14);
Coil (4), said housing portion (10b) in the stowed conductor remote from the neutral point (14) from the top of the neutral point (14) lead in the vicinity (15) (13) is wound around The accommodating portion (10b) includes a conductive wire (15) near the neutral point (14) accommodated in the accommodating portion (10b) and a conductive wire (15) near the neutral point (14) ( 15) In the method of manufacturing a rotor configured so as not to contact the conductive wire (13) separated from the neutral point (14) wound from above ,
After receiving the neutral point (14) lead in the vicinity (15) into said receiving portion (10b), away conductive wire (13) from the neutral point (14) housed in the housing portion (10b) A method of manufacturing a rotor, wherein the coil (4) is formed by winding from above a conducting wire (15) near the neutral point (14) .

In the manufacturing method of the rotor according to claim 5,
The core (2) is formed with a plurality of radially extending teeth pieces (9) for winding the conducting wire (13), and the axial end surface of the core (2) is provided with the core (2). An insulating part (7) for insulating the metal part (6) and the conducting wire (13) is provided,
The core (2) from the housing part (10b) formed in the insulating part (7) so that the conductive wire (15) near the neutral point (14) extends in the same direction as the teeth piece (9). Between a pair of convex portions (11) formed on the radially outer side of
Accommodated before Kitotsu portion (11) from the subsequent neutral point (14) before KiOsamu ml portion of wire (15) in the vicinity of the (10b),
Method of manufacturing a rotor and forming the coil was wound around distant conductor (13) than in the radially inner front Kitotsu portion (11) from the neutral point (14) (4).