JP4587256B2 - Commutator, commutator manufacturing method, and fuel pump - Google Patents

Commutator, commutator manufacturing method, and fuel pump Download PDF

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Publication number
JP4587256B2
JP4587256B2 JP2001156022A JP2001156022A JP4587256B2 JP 4587256 B2 JP4587256 B2 JP 4587256B2 JP 2001156022 A JP2001156022 A JP 2001156022A JP 2001156022 A JP2001156022 A JP 2001156022A JP 4587256 B2 JP4587256 B2 JP 4587256B2
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commutator
protrusion
piece
hole
commutator piece
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JP2002064958A (en
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雄介 原
省一 竹ノ内
聡 杉山
正広 高浜
顕三 清瀬
芳弘 寺本
登 吉川
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TRIS Inc
Denso Corp
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TRIS Inc
Denso Corp
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Description

【０００１】
【発明の属する技術分野】
本発明は、整流子、整流子の製造方法及び燃料ポンプに関する。
【０００２】
【従来技術】
円盤面状の整流面を有する円盤型整流子は、たとえば燃料ポンプ一体型モ−タなどに装備されている。近年、この燃料ポンプ一体型モ−タにおいて、燃料に含まれる硫黄不純物への対策として、この円盤型整流子を、放射方向に延在する複数のスリットにより分割されて全体として略円盤形状の整流面を有する複数の整流子片（主としてカ−ボン焼成物）と、各整流子片に個別に接合される複数の金属片と、整流子片の整流面を露出させつつ整流子片−金属片の各対を支持する樹脂製のボス部とで構成して、回転軸に嵌着することが行われている。
【０００３】
上記した整流子片と金属片との接合に関して、金属片が整流子片の反整流面側に接合する反整流面接合構造と、金属片が整流子片の径外側の外側面に接合する外側面接合構造とが知られている。
【０００４】
しかし、反整流面接合方式では、単に機械的に密着させるだけでは、金属片のスプリングバックなどにより整流子片の反整流面側の端面と金属片の平坦面との接合性が悪く、接合にはこれら軸方向に強く押し付けつつ両者をはんだやその他の溶融接合技術により接合する必要があり、カ−ボン整流子片と金属片との溶融接合の例も提案されてきた（特開平５−３０１７０）が、その後の工程で金属片の端子部にフュージング加工しにてコイル導線を接合する際に熱が発生することを考えると、溶融接合ではせっかく接合した半田等がその熱で溶けてしまい、歩留まりが低下するという問題があり、大量生産に適するものと言えなかった。
【０００５】
この問題に対して、特開平１０−４６５３号公報は、反整流面接合構造の円盤型整流子において、整流子片の反整流面側の端面に軸方向に突部を設け、この突部に金属片の孔を嵌着し、金属片の孔の周囲を変形によりかしめて両者の軸方向相対変位を防止して、上記溶融接合なしに整流子片と金属片との良好な電気的接触を図っている。また、この公報には、突部と孔とを係合一体化する構成の例として、孔に対して突部を圧入する構成も記載されている。
【０００６】
【発明が解決しようとする課題】
しかしながら、上記した公報の整流子片−金属片接続方式では、先端に複数の切り込み突起をもつ円筒状のかしめ具を金属片の孔の周囲に押し込み、これにより整流子片の突部周囲の金属片を切り込んで金属片の孔近傍部分を孔側へ塑性変形させ、これにより実質的に孔を縮径して金属片の突部と金属片の孔周囲との接触強化を行うという作業を行い、金属片が軸方向反整流子片側へ変位するのを防止している。
【０００７】
このため、以下の問題を生じた。
【０００８】
まず、上記切り込みかしめの深さ、又は、切り込みにより突部側へ倒れて突部に密着する切り込み片の厚さや倒れ量を一定に制御することが容易ではない。
【０００９】
また、かしめ具の軸心位置と金属片の穴の中心とを高精度に位置合わせする必要があり、もし両者がずれると、複数の切り込み片の一部は薄くなり、それと１８０度反対位置では切り込み片は厚くなり、その結果、突部と孔との間の隙間が電気的又は機械的な接触の確保しにくい状態となる。
【００１０】
同様に、金属片の孔及び整流子片の突部の寸法精度、形成位置精度、挿入時の相対位置精度を、特に径方向において高く確保する必要があった。これらの精度が劣ると、孔と突部との接触面の一部が接触不良となり、両者の接触部の電気抵抗が増加したり、もろい突部に損傷が生じたりする。
【００１１】
また、単に圧入する構成では、係合一体化することができるだけであり、突部と孔との位置ばらつきがあると、孔の内周面と突部との間に隙間が生じ、導通や固定の品質が確保できないという問題がある。突部が複数設けられた整流子片では互いの突部の位置ばらつき、孔の位置ばらつきが生じやすいため、上記問題は特に重要である。
【００１２】
本発明は上記問題点に鑑みなされたものであり、構造及び製造工程の複雑化を抑止し、整流子片の損傷を防ぎつつ、整流子片と金属片との良好な電気的、機械的接触を実現可能な整流子、整流子の製造方法及び燃料ポンプを提供することを、その目的としている。
【００１３】
【課題を解決するための手段】
請求項１記載の整流子の製造方法は、互いに所定ギャップを隔てつつ軸心周囲に放射状に配置されて全体として略円盤形状の整流面を有するとともにカーボン焼成物を含む複数の整流子片、各前記整流子片の主として反整流面側の表面に接して前記整流面を露出させつつ前記各整流子片を支持し保護する樹脂製のボス部、及び、各前記整流子片の反整流面側の表面に接合される整流子片接続部、及び、前記整流子片接続部の径外側の端部から前記ボス部の前記主部の外周面に沿って延在して巻線が接合される端子部をそれぞれ有する複数の金属片を備え、前記整流子片は、前記整流面を有する基板部、及び、前記基板部の反整流面側の表面から突出する突部を有し、各前記金属片の前記整流子片接続部は、前記突部が挿入される孔をそれぞれ有する整流子の製造方法において、前記孔への前記突部の挿入後にて前記孔に接する予定の領域である前記突部の予定接触領域の全面を前記挿入前にて前記孔より径大に形成し、前記挿入に際して、前記金属片の前記孔に面する部位が前記突部の外周面をシェービングし、前記突部の基端部の外周面に面して前記基端部と前記金属片との間に、前記整流子片の突部の削り粉を収容するポケットを形成することを特徴としている。なお、本明細書でいうシェービングとは、突部を削りながら挿入することを意味するものとする。
【００１４】
すなわち、本構成によれば、突部の径（特に、挿入完了後、孔の内周面に接する予定接触領域の径）を、その全面にわたって、孔の径よりも大きく形成する。
【００１５】
このようにすると、突部の余分な部分は、整流子片が主としてカ−ボン焼成物からなるため上記挿入時に金属片の孔の周縁部により容易に削られ、その結果として、従来のように上記かしめ作業を行わない場合でも、孔と突部とがその予定接触領域において良好に密着することができる。
【００１６】
これは、突部を孔にシェービングしつつ挿入（圧入）する際に、金属片の孔の周縁部が突部の余分な部分を削るとともに残った突部の外周面を径内側へ圧縮し、突部のこの外周面と孔の内周面とがその反力で密着することができるためである。
【００１７】
なお、この予定接触領域は、孔の内周面すべてに設定してもよく、又は孔の内周面の所定部分に設定してもよい。
【００１８】
また、本構成によれば、突部の全周において突部が金属片から受ける上記反力（略求心方向）は略一定となり、突部の一部に挿入時の応力が集中して突部にクラックなどの機械的損傷が生じるのを防止することができる。
【００１９】
更に、上記した従来技術のようなかしめ工具を用いた加工を必要としないので、かつ、挿入と突部の削りとを同一工程で行うので、製造工程の簡素化を実現することができ、かしめによる突部の損傷も防止することができる。
そして、挿入時に孔が突部の側面部（周面部）を削ることにより生じた削り粉をこのポケットに収容することができるので、削り粉が整流子片の基板部と金属片との間に介在して、整流子片の基板部と金属片（の整流子片接続部）との電気的接触が低下することを抑止することができる。
【００２０】
請求項２記載の整流子の製造方法は、互いに所定ギャップを隔てつつ軸心周囲に放射状に配置されて全体として略円盤形状の整流面を有するとともにカーボン焼成物を含む複数の整流子片、各前記整流子片の主として反整流面側の表面に接して前記整流面を露出させつつ前記各整流子片を支持し保護する樹脂製のボス部、及び、各前記整流子片の反整流面側の表面に接合される整流子片接続部、及び、前記整流子片接続部の径外側の端部から前記ボス部の前記主部の外周面に沿って延在して巻線が接合される端子部をそれぞれ有する複数の金属片、を備え、前記整流子片は、前記整流面を有する基板部、及び、前記基板部の反整流面側の表面から突出する突部を有し、各前記金属片の前記整流子片接続部は、前記突部が挿入される孔をそれぞれ有する整流子の製造方法において、前記挿入前に、前記各整流子片を一体に形成して整流子片一体物とし、かつ、前記各金属片を一体に形成して金属片一体物とし、前記各整流子片一体物における前記各突部の径及び径方向突部中心位置の製造公差と、前記各金属片一体物における前記各孔の径及び径方向孔中心位置の製造公差と、前記整流子片一体物と金属片一体物との間の径方向位置合わせ公差との合計からなる前記突部の外周面と前記孔の内周面との間の径方向位置ばらつきの総和よりも、前記突部の予定接触領域を前記挿入前にて前記孔より径大に形成し、前記孔への前記突部の挿入後にて前記孔に接する予定の領域である前記突部の予定接触領域の全面を前記挿入前にて前記孔より径大に形成し、前記挿入に際して、前記金属片の前記孔に面する部位が前記突部の外周面をシェービングすることを特徴としている。
【００２１】
本構成によれば、挿入前の突部と孔との径方向位置の製造公差や、孔や突部の径の製造公差を大きくすることができるため、孔と突部との接触抵抗の増大を招くことなく製造工程を格段に容易とすることができる。また、挿入時に孔が突部の側面部（周面部）を削ることにより生じた削り粉をこのポケットに収容することができるので、削り粉が整流子片の基板部と金属片との間に介在して、整流子片の基板部と金属片（の整流子片接続部）との電気的接触が低下することを抑止することができる。
【００２２】
請求項３記載の整流子の製造方法によれば、孔の直径の３％以上とする数値範囲の選択により、突部と金属片（孔）との接触性を向上して電気抵抗値の低減、機械的強度の向上を実現できることが、本発明者らの実験から見いだされた。
【００２３】
請求項４記載の整流子の製造方法によれば、プレスによる打ち抜き加工により孔に形成された「だれ面」の大きさを、更にシェービング加工することにより容易に前記突部外周面のシェービングに適した所望量にすることができる。
【００２４】
請求項５記載の整流子によれば、孔の内周面に接触する突部の外周面が、孔の内周面で形成されたカーボン焼成物の削り面となっているので、突部の外周面は削られた反力で孔の内周面に良好に密着して接触する。これにより、良好な電気的、機械的接触をもつ整流子を実現することができる。また、挿入時に孔が突部の側面部（周面部）を削ることにより生じた削り粉をこのポケットに収容することができるので、削り粉が整流子片の基板部と金属片との間に介在して、整流子片の基板部と金属片（の整流子片接続部）との電気的接触が低下することを抑止することができる。
【００２５】
ところで、この削り面とは、突部が孔に挿入されることにより、突部を形成する粒子が剥落した表面形状を言い、これに対して、圧入では、突部を形成する粒子は全体的に押しつぶされ、ここでいう削り面と異なる。
【００２６】
請求項６の記載によれば、軸方向に延在する前記孔の内周面と、径方向に延在する前記整流子片の前記反整流面に対向する前記金属片の実質的な平坦面との交差領域からなる前記周縁角部は、丸みを有する面取り部又はプレス垂れ部を有し、前記面取り量又はプレス垂れ量は、前記内周面と前記平坦面との交差点から前記内周面方向及び径方向へ０．２ｍｍ以下の領域に有ることを特徴としている。
【００２７】
更に、本発明者は、孔を囲む金属片の整流子片側の平坦面部分である周縁角部の丸みが少ないほど、シェービング時における突部の亀裂、破損が低減できることを実験により見いだした。更に、本発明者は、上記丸みが０とした内周面と平坦面との理想的な交差点から内周面方向及び径方向へ０．２ｍｍ以下に上記丸みを抑止すれば、突部の亀裂、破損が低減できることを実験により見いだした。
【００２８】
請求項７の記載よれば、シェービングによる締結において、電気抵抗値を所望の値とすることができる。
【００２９】
請求項８の記載によれば、より容易に所望の電気抵抗値を得ることができる。
【００３１】
請求項９の記載によれば、金属平板から金属片をプレス加工による形成する際、孔の周縁部に生じる垂れ、もしくはプレスによって加工される面取り部に隣接するギャップが上記ポケットを構成するので、ポケット形成のために整流子片成形用金型又は金属片加工用金型に複雑な形状加工を施す必要がなく、製造コストを低減することができる。
【００３２】
請求項１０の記載によれば、孔と突部とが位置ずれしたとしても、孔の内周面と突部との間に形成される隙間を低減して密着する部分の軸方向距離を増大することができるので、電気的、機械的接続を良好かつ容易に確保することができる。
【００３３】
請求項１１の記載によれば、突部の型抜き、突部の孔への挿入が容易となる。
【００３４】
請求項１２の記載によれば、孔と突部との接触面積を増大できるとともに、シェービング挿入の際に孔が突部に与える圧縮力も増大することができ、両者の接触電気抵抗を一層低減することができる。
【００３５】
また、上記凹部が、挿入時に孔が突部の側面部（周面部）を削ることにより生じた削り粉を収容する上記ポケットを構成するので、削り粉が整流子片の基板部と金属片との間に介在して、整流子片の基板部と金属片（の整流子片接続部）との電気的接触が低下することを抑止することができる。
【００３６】
請求項１３の記載によれば、硫黄分を不純物として含有する燃料を昇圧する直流電動機一体型燃料ポンプの整流子の耐久性を向上することが可能となる。
【００３７】
【発明の実施の形態】
本発明の好適な態様を以下の実施例により説明する。もちろん、本発明の形態は、以下の実施例に限定されるものではない。
【００３８】
【実施例１】
この実施例の整流子を図１を参照して説明する。
【００３９】
（全体構造）
この整流子は、整流子片１、金属片２、ボス部３からなり、燃料ポンプと一体のモ−タに装備される。
【００４０】
整流子片１は、複数個設けられ、各整流子片１は、互いに周方向に所定ギャップを隔てつつ軸心周囲に放射状に配置されるとともに焼結して形成されており、全体として輪板面状をなす整流面１０を有している。整流子片１は、カ−ボン粉からなる表面部１１と、表面部１１の反整流面側に設けられて金属粉（たとえば銅粉）とカ−ボン粉との混合粉からなる裏側部１２と、裏側部１２から軸方向反整流面側へ突設されて金属粉（たとえば銅粉）とカ−ボン粉との混合粉からなる突部１３とからなる。この金属粉により、突部１３の固有抵抗は３０００μΩ・ｃｍ以下となっている。
【００４１】
金属片２は、複数個設けられ、裏側部１２の反整流面側の表面に個別に接合される整流子片接続部２１、及び、整流子片接続部２１の径外側の端部から後述するボス部３の外周面に沿って軸方向へ延在する軸方向延在部２２、軸方向延在部２２の反整流面側の端部から径外側及び整流子片１側へ突出して図示しない電機子コイルの先端がフユ−ジング加工により接続される端子部２３を有している。
【００４２】
ボス部３は、樹脂により厚肉輪盤形状に形成されており、径方向中央部にシャフト孔３０を有している。また、ボス部３は、金属片２の整流子片接続部２１の表面のうち、整流子片１と接合しない部分を被覆している。更に、ボス部３は、各整流子片１の整流面及び周方向の側面を除いて各整流子片１の表面を被覆している。
【００４３】
金属片２の整流子片接続部２１は孔４を有しており、整流子片１の突部１３が孔４に嵌入され、突部１３の外周面１３２のうちこの突部の軸方向における大部分を占める削り面１３２ａが孔４の内周面４１に密着している。同時に、整流子片接続部２１の図１中、上面は整流子片１の裏側部１２の反整流面側の表面に密着し、また、裏側部１２内に入れた金属粉とも相まって両者間に良好な電気的接触を確保している。なお、整流子片１と金属片２とを熱的に接合することも可能である。
【００４４】
（製造方法）
まず、各整流子片１を一体化した形状にカ−ボン焼結により作製された正確には略輪板形状の円盤と、各金属片２を所定形状の接続部により一体化した形状にプレス加工により作製された金属板とを準備する（図２参照）。
【００４５】
突部１３の径は孔４の径よりも所定寸法Ｌだけ大きく作製されている。また、突部１３の頂面１４の周縁部は面取りされており、頂面１４の径は孔４より径小とされている。これについては後述するが、孔４への突部１３の嵌入を容易化するためである。更に、突部１４と孔４との位置ずれに対しても、電気的・機械的な接続を良好に維持するためである。更に、整流子片１の裏側部１２は、突部１３の基端部に接しつつそれを囲んでリング状の凹部１５を有している。この凹部１５は本発明でいう削り粉収容用のポケットをなす。
【００４６】
図２２を参照して更に詳細に説明する。
【００４７】
この実施例では、整流子片１の突部１３の頂面１４と外周面（側面）１４０とが交わる周縁角部１３０は全周にわたってなだらかに面取りされ、周縁角部テーパ面１３０が形成されている。
【００４８】
突部１３の周縁角部テーパ面１３０が面取りされていることにより、圧入開始時に、突部１３の頂面１４はすべて孔４内に入り、孔４の周縁角部２１０は突部１３の周縁角部テーパ面１３０に斜めに当接することになる。このようにすれば、孔４の周縁角部２１０から突部１３の周縁角部テーパ面１３０に径方向圧縮力を付与するのに有利となる。
【００４９】
したがって、両部材の製造公差や圧入時の相対位置合わせ誤差（径方向）の合計を所定許容値以下に調整した場合に、この突部１３の周縁角部テーパ面１３０が常に孔４の周縁角部２１０に当接し、かつ、好適なシェービング締結代が確保できるように、シェービング締結代、周縁角部テーパ面１３０の内径、外径が設定される。
【００５０】
これにより、両部材の製造公差や圧入時の相対位置合わせ誤差（径方向）の合計が所定許容値以下であれば、好適な結合をなすことができる。
【００５１】
また、周縁角部テーパ面１３０は、なだらかなテーパ面で面取りされているので、整流子片接続部２１と突部１３との間の位置ずれに対して、孔４内に突部１３が挿入される体積をより大きくすることができる。すなわち、位置ずれが大きくても、孔４と突部１３との間に隙間が生じるのを防げ、これによる電気的・機械的接続の低下を容易に防止することができる。
【００５２】
また、図２２において、突部１３の外周面１４０は先細テーパ面となっている。すなわち、突部１３は、切頭円錐形状に形成されている。これにより、焼結後における型からの突部１３の抜き出しが容易となる。
【００５３】
次に、この円盤の反整流面側の端面から突出する突部１３を各金属片２の整流子片接続部２１の孔４に圧入する。突部１３はカーボン粉を主成分とする焼結体であるためもろく、その結果、突部１３のうち孔４に入り切らなかった部分は、この圧入時に整流子片接続部２１の孔４の周縁部により削がれて突部１３から剥離し、整流子片接続部２１に押されて又は重力により凹部１５にほとんど収容される。
【００５４】
この状態を図３に示す。
【００５５】
整流子片接続部２１の反整流子片側端面２１２から突部１３の頭部１３１が突出している。頭部１３１は周縁角部テーパ面１３０のうち、孔４の周縁角部２１０で削られずに残った部分と頂面１４とで形成されている。
【００５６】
特に、この実施例においては、頭部１３１が反整流子片側端面２１２から突出することにより、孔４の内周面４と突部１３の外周面１３２とが突部１３の軸方向長すべてにわたって良好に密着している。
【００５７】
これは、テーパ面１３０がなだらかであることが寄与しており、テーパ面１３０が急峻である場合には、孔１４と突部１３とが位置ずれすれば、内周面４１と突部１３との間に隙間ができ、軸方向の密着長さが減少してしまう。
【００５８】
圧入が完了すると、金属片２の整流子片接続部２１の図１中、上面は裏側部１２の図１中、下面に密接し、かつ、突部１３の外周面が孔４の内周面に上記圧入時に突部１３に作用する圧縮力の反力により強く密接する。
【００５９】
次に、この一体物を金型にセットし、樹脂インサ−ト成形又は樹脂モ−ルド成形により、ボス部３を成形する。これにより、金属片２の整流子片接続部２１はボス部３中に埋設され、金属片２の軸方向延在部２３は、ボス部３の外側面に密着して軸方向に延在する。
【００６０】
次に、回転円盤刃により上記円盤を整流面１０側から所定深さまで放射方向にカットして複数のスリットを形成し、上記円盤を所定個数の整流子片１に分断し、同時に各金属片２を繋ぐ上記接続部もカットして各金属片２を分断する。
【００６１】
最後に、フユ−ジング加工により、金属片２の端子部２３に銅線を接合する。
【００６２】
上記したこの実施例の整流子及びその製造方法によれば、
構造及び製造工程を複雑化することなく、かつ、整流子片の損傷確率を増大することなく、反整流面接合構造の円盤型整流子における整流子片と金属片との良好な電気的接触を実現することができる。
【００６３】
この実施例の整流子の他の特徴を以下に説明する。
【００６４】
まず、突部１３の径（特に、挿入完了後、孔４の内周面に接する予定接触領域の径）を、その全面にわたって孔４の径よりも大きく形成している。なお、ここでいう予定接触領域とは、孔４により削られた後、孔４の内周面に径方向に対面する突部１３の外周面の領域をいうものとする。
【００６５】
このようにすると、突部１３の余分な部分は、整流子片が主としてカ−ボン焼成物からなるもろい特性をもつために金属片の孔の周縁部により容易に削られ、その結果として、突部１３は孔４に良好に密着することができる。これは、突部１３を孔４に挿入（圧入）する際に、孔４の周縁部が突部１３の余分な部分を削るとともに残った突部１３の外周面を径内側へ圧縮するため、突部１３の外周面１３２のうち密着面１３２ａと孔４の内周面とがその反力で良好に密着するからである。なお、この外周面１３２は、本発明で言う削り面であり、密着面１３２ａも削り面である。すなわち、突部を形成する粒子が剥落した面になっている。
【００６６】
次に、上記挿入時に、突部１３が孔４から受ける機械的力は突部１３の全周において略一定となり、突部１３の一部に挿入時の応力が集中することがないので、突部１３への機械的損傷の発生を抑止することもできる。
【００６７】
次に、この実施例では、上記円盤すなわち各整流子片一体物における各突部１３の径及び位置の製造公差と、上記金属板すなわち各金属片一体物における各孔４の径及び位置の製造公差と、これら整流子片一体物と金属片一体物との間の径方向位置合わせ公差との合計からなる突部１３の外周面と孔４の内周面との間の圧入直前時の径方向位置ばらつきの総和よりも、突部１３の予定接触領域における突部１３と孔４との径方向寸法差を大きく設定している。これにより、上記製造公差や位置合わせ公差（製造上、あらかじめ見込んだ位置合わせ誤差マージン）を大きく設定しても、突部１３と孔４とは予定接触領域の全面においてすべて密着することができ、製造工程を簡素としつつ上記効果を確保することができる。
【００６８】
次に、この実施例では、分断前の金属片一体物をプレス加工により金属平板を厚さ方向一方側から他方側へ打ち抜いて作製しているが、この時、金属片２の整流子片接続部２１の孔４の他方側の周縁部は打ち抜き方向に押し曲げられ、いわゆるバリとなる。このため、整流子片接続部２１の孔４の周縁部の一方側は孔４へ向けて落ち込む連れ曲がり部（いわゆるだれ部あるい垂れ部）となる。この実施例では、突部１３をこの連れ曲がり部側から孔４に挿入する。このようにすると、割れなしに挿入する作業の能率を向上することができ、更にこの連れ曲がり部が凹んでいる分だけ、上記ポケットすなわち凹部１５の削り粉収容量を増大することができる。なお、予定削り粉量が少ない場合には、凹部１５を省略し、上記整流子片接続部２１の上記連れ曲がり部と、整流子片１の基板部１２との間のスペースをポケットとしてもよい。また、このポケットを整流子片１側ではなく、金属片２の孔４の周縁部に設けてもよい。
【００６９】
孔４は、通常打ち抜きでは厚みの１割程度のだれ（垂れともいう）が生じるので、だれ量が大きいとシェービング圧入時に突部にクラックが生じる。これを防ぐためには、打ち抜き後に更に金属片２をシーエビング穴加工することにより、だれ量を容易に突部の外周面のシェービングに適した所望量とするとすることができる。この実施例では、金属片の板厚を１ｍｍとしており、更に打ち抜き後にシェービング穴加工している。なお、ここでいうシェービング穴加工とは、穴内周のだれ面の一部を削りとり、軸方向の大小量を小さくすることを言う。
【００７０】
【実施例２】
本発明の他の実施例を図４〜図８を参照して説明する。ただし、整流子片１及び金属片２は重要部分以外を示している。
【００７１】
この実施例では、整流子片１の突部１３の外周面は周方向所定ピッチでそれぞれ軸方向に延在する８個の条溝部が形成され、周方向に隣接する任意の２つ条溝部の間にはそれぞれ軸方向に延在する突条部が形成されている。突部１３の中心線から上記条溝部の溝底面までの径は、金属片２の孔４の径よりも小さく形成され、突部１３の中心線から上記突条部の頂面までの径は、金属片２の孔４の径よりも大きく形成されている。これにより、突部１３を孔４に挿入する際に、突部１３の上記突条部の頂面近傍部分が削られて両者が緊密に接触する（図８参照）。また、金属片２の孔４の内周面と突部１３の上記条溝部との間にはスペース（ポケット）が形成され、削られたカーボン粉を収容する。
【００７２】
【実施例３】
本発明の他の実施例を図９〜図１３を参照して説明する。ただし、整流子片１及び金属片２は重要部分以外を示している。
【００７３】
この実施例では、実施例２と逆に、金属片２の孔４の内周面は周方向所定ピッチでそれぞれ軸方向に延在する８個の条溝部が形成され、周方向に隣接する任意の２つ条溝部の間にはそれぞれ軸方向に延在する突条部が形成されている。孔４の中心線から上記条溝部の溝底面までの径は、突部１３の径よりも大きく形成され、孔４の中心線から上記突条部の頂面までの径は、突部１３の径よりも小さく形成されている。これにより、突部１３を孔４に挿入する際に、孔４に面する金属片２の上記突条部は突部１３の外周面を削って両者が緊密に接触する（図１３参照）。また、金属片２の孔４の上記条溝部と突部１３の外周面との間にはスペース（ポケット）が形成され、削られたカーボン粉を収容する。
【００７４】
【実施例４】
本発明の他の実施例を図１４を参照して説明する。ただし、整流子片１及び金属片２は重要部分以外を示している。
【００７５】
この実施例では、金属片２の整流子片接続部２１が、孔４０の内周面に軸方向に延在する８個の突条部（小突起）４１と、隣接する突条部４１，４１の間に形成される８個の凹部４２を有する点が、実施例１の孔４と異なっている。この実施例では、孔４０に圧入される突部１３はその全周にわたって突条部（小突起）４１及び凹部４２の表面に接触している。このようにすれば、突部１３と孔４０との接触面積を更に稼ぐことができ、両者の接触抵抗を一層低下することができる。なお、金属片２の整流子片接続部２１に設ける孔４、４０は、多数設けてもよくかつ形状自由である。
【００７６】
【実施例５】
他の実施例を図１５を参照して以下に説明する。
【００７７】
孔４から突部１３を引き抜くのに要する引抜力（締結力）とシェービング締結代との関係（引抜力・シェービング締結代特性）を図１５に示し、図１６にシェービング締結代とシェービング（削り）代及び弾性代との関係を示す。
【００７８】
シェービング締結代とは、シェービング（削り）代及び弾性代の合計を言い、シェービング代とは、孔４の内径より所定値以上大きく作製された径を有する突部１３を金属片２のの孔４に圧入する際に孔４に入りきれずに削ぎ落とされる突部１３の外周部を言い、弾性代とは、圧入された突部１３が径方向弾性圧縮される際の径方向縮み量を言う。
【００７９】
この突部１３の径方向縮み量（弾性代）は、突部１３を孔４から引き抜くのに要する引抜力に相関関係をもつ筈である。すなわち、生じる引き抜き時の摩擦力（引抜力）は、接触面積と摩擦係数と圧縮力との積に略比例する筈であり、引抜力は圧縮力に略比例するため、引抜力により突部１３と金属片２との機械的結合の強弱を判定することができる。
【００８０】
図１５からわかるように、シェービング締結代と引抜力（ひいては圧縮力、更にひいては弾性代）とは、シェービング締結代の増加とともに、それに比例して増大するが、ある値（図１５ではシェービング締結代が孔径の３％で引抜力はピーク値となり、その後はシェービング締結代を増加しても引抜力は増加することはなく僅かに減少する。
【００８１】
上記実験により、シェービング締結代を孔径の３％以上とすることで引抜力のピーク値が得られ、突部１３と孔４との良好な機械的結合と低い電気抵抗値とが実現できることがわかった。
【００８２】
図１７に、図１５、図１６と同一の実験条件における突部１３と金属片２との電気抵抗値とシェービング締結代との関係を示す。図１７から、電気抵抗値は、まさしく弾性代の逆数に相似する特性を有することがわかる。したがって、あらかじめこの電気抵抗値とシェービング締結代との関係を示す電気抵抗値・シェービング締結代特性を実験で求めておき、電気抵抗値が所望値以下になる範囲にシェービング締結代を設定することにより、低電気抵抗値と良好な結合を実現することができる。
【００８３】
また、図１６から、実験によりあらかじめ弾性代とシェービング代又は前記シェービング締結代との関係を示す弾性代・シェービング代特性又は弾性代・シェービング締結代特性を求めておき、この特性上において弾性代が所望値以上になるようにシェービング締結代を決定しても低電気抵抗値と良好な結合を実現することができる。
【００８４】
なお、金属片２の整流子片接続部２１に複数の孔４を設け、整流子片１に複数の突部１３を設けることが好適であるが、このような形状の複雑化は種々の製造公差のばらつきにより、突部１３が孔４に対して径方向に位置ずれして初期のシェービング締結代が得られない場合がある。
【００８５】
なお、孔径ばらつき、突部径ばらつき、孔の芯ずれ、突部の芯ずれ及び孔の直径の３％の総和がシェービング締結代以下であることが望ましい。
【００８６】
（変形態様）
なお、カ−ボン焼成物からなるカーボン円盤に複数の突部１３を設け、金属円盤に複数の孔４を設け、各突部１３を各孔４に個別に圧入し、カーボン円盤及び金属円を放射状に所定個数に切断して、カーボン円盤から整流子片１を、金属円から金属片２を形成することが行われる。したがって、この場合には、カーボン円盤の各突部１３と金属円盤の各孔４との製造公差及び位置合わせ誤差の合計を加味してもなおシェービング締結代が好適値となるように、シェービング締結代の設定値が決定される。この場合、分割後の各整流子片１は一個乃至複数の突部１３をもち、分割後の各金属片２がそれぞれ一個乃至複数の孔４をもつことができる。各部材の製造公差の合計及び圧入時の相対位置合わせ誤差の合計が所定の許容最大値以下であれば、各突部１３の全周にわたって好適なシェービング締結代が得られるようにシェービング締結代、及び、製造公差（部材寸法ばらつき）の合計及び圧入時の相対位置合わせ誤差の合計の許容値を、設定すれば、低い電気抵抗値と良好な機械的結合とを実現することができる。
【００８７】
【実施例６】
他の実施例を図１８を参照して以下に説明する。
【００８８】
突部１３の圧入時における上記シェービングは、孔４を囲む整流子片接続部２１の周縁角部２１０の形状に関係する。なお、この周縁角部は当然、整流子片接続部２１の整流子片１側の孔４の開口端に存在する。すなわち、この周縁角部２１０の凹みが小さく、シャープであれば、シェービングが良好となり、シェービング時における突部１３のクラックの発生はない。
【００８９】
図１５〜図１７の実験と同一条件にて、孔４の周縁角部２１０を、図１８に示すように、整流子片接続部２１の内周面４００、平坦面４０１に対してそれぞれ４５度の角度で平面面取りした場合の周縁角部２１０の大きさ（凹み量）と、圧入時の突部１３の破損状況との関係を調べた。その結果を図１９に示す。図１９から、Ａ＝Ｂを０．２ｍｍ未満とすれば、突部１３の破損なしにシェービング・圧入を実施できることがわかる。なお、Ａ＝Ｂ＝０．２ｍｍである場合、シェービング締結代にかかわらず割れが発生するため、少なくとも寸法Ａ、Ｂのいずれかは０．２ｍｍ未満とする必要がある。
【００９０】
この周縁角部２１０は、図２０に示すように孔４をプレス加工により打ち抜く場合のプレス垂れ部２１００で形成されてもよく、内周面４００をプレス成形後のシェービング穴加工により面取りを所望の値で形成してもよい。
【００９１】
【実施例７】
上記説明した整流子を適用した車両用の直流電動機一体型燃料ポンプの全体構成を図２３に示し、その整流子部分の拡大図を図２４に示す。
【００９２】
ケーシング５００には直流モータ５０１が内蔵されており、直流モータ５０１は、ステータ５０１１、電機子５０１２、回転軸５０１３、整流子５０１４、ブラシ５０１５を有している。５０１６、５０１７は軸受けである。
【００９３】
回転軸５０１３の一端部は、ポンプ６００と直流モータ５０１とを軸方向に隔てる隔壁５００１を貫通してポンプ６００側に突出しており、この回転軸５０１３の一端部にポンプ６００の回転翼６０１が設けられている。６０２は燃料吐出口であり、燃料吸入口は図示省略している。整流子５０１４は、電機子５０１２に隣接して回転軸５０１３の他端部に固定され、ブラシ５０１５が整流子５０１４に摺接している。
【００９４】
この種の車両用の直流電動機一体型燃料ポンプの構成及び動作自体は周知であるので、更なる詳細説明は省略する。
【００９５】
この実施例によれば、硫黄分を不純物として含有する燃料を昇圧する車両用直流電動機一体型燃料ポンプの整流子の耐久性、特に整流子片１の突部１３の耐久性を向上し、ポンプ寿命を向上することができる。
【００９６】
（変形態様）
実施例では、突部１３に選択的に銅粉などの金属粉を混入することにより、電流が集中する突部１３の抵抗損失を一層低減している。他に、低抵抗カーボン層により、突部１３の比抵抗を３０００μΩ・ｃｍ以下としてもよい。
【００９７】
（変形態様）
上記実施例では、金属円盤の孔４に、カーボン円盤の突部１３を圧入した後、これら金属円盤・カーボン円盤一体物を放射切断したが、圧入前に両者の一方又は両方をあらかじめ放射切断することも可能である。
【００９８】
（変形態様）
上記実施例では、整流子は円盤面状の整流面を有していたが、整流面を円筒面状に形成してもよい。
【００９９】
なお、上記説明した部材の製造公差（寸法許容ばらつき）としては、孔４間のピッチずれ、孔４の径ばらつき、突部１３のピッチずれ、突部１３の半径ばらつきがある。
【０１００】
（変形態様）
上記実施例では、垂れ面が有する板厚方向の端部に形成されているが、図２５、図２６に示すように、孔４ａの開口部に位置して整流子片接続部２１ａに大径の円盤状凹部を形成し、この円盤状凹部に接する孔４ａの境界部分に、垂れ面を形成してもよい。
【図面の簡単な説明】
【図１】実施例１の整流子の軸方向半断面図である。
【図２】実施例１の整流子の圧入前の位置合わせ状態を示す模式断面図である。
【図３】実施例１の整流子の圧入後の状態を示す模式断面図である。
【図４】実施例２の金属片の平面図である。
【図５】実施例２の厚さ方向断面図である。
【図６】実施例２の整流子片の平面図である。
【図７】実施例２の整流子片の厚さ方向断面図である。
【図８】実施例２の整流子片と金属片との嵌合状態を示す断面図である。
【図９】実施例３の金属片の平面図である。
【図１０】実施例３の厚さ方向断面図である。
【図１１】実施例３の整流子片の平面図である。
【図１２】実施例３の整流子片の厚さ方向断面図である。
【図１３】実施例３の整流子片と金属片との嵌合状態を示す断面図である。
【図１４】実施例４の整流子片と金属片との嵌合状態を示す断面図である。
【図１５】引抜力・シェービング締結代特性を示す特性図である。
【図１６】シェービング代及び弾性代とシェービング締結代との関係を示す特性図である。
【図１７】電気抵抗値とシェービング締結代との関係を示す特性図である。
【図１８】金属片の周縁角部の面取り状態を示す軸方向部分断面図である。
【図１９】図１８の周縁角部による各シェービング締結代値における突部１３の破損状況を示す図である。
【図２０】図１８の周縁角部をプレス垂れ部で形成した例を示す軸方向部分断面図である。
【図２１】図１８の周縁角部をシェービング加工で形成した例を示す軸方向部分断面図である。
【図２２】周縁角部が面取りされた突部を示す軸方向断面図である。
【図２３】燃料ポンプの全体構成図である。
【図２４】図２３の整流子近傍の拡大図である。
【図２５】周縁角部をプレス垂れ部で形成した変形態様を示す軸方向部分断面図である。
【図２６】周縁角部をシェービングで形成した変形態様を示す軸方向部分断面図である。
【符号の説明】
１ 整流子片
２ 金属片
３ ボス部
４ 孔
１３ 突部
１５ ポケット
２１ 整流子片接続部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a commutator, a commutator manufacturing method, and a fuel pump.
[0002]
[Prior art]
A disc-type commutator having a disc-shaped commutation surface is provided, for example, in a motor integrated with a fuel pump. In recent years, in this fuel pump integrated motor, as a measure against sulfur impurities contained in the fuel, this disk-type commutator is divided by a plurality of slits extending in the radial direction to form a generally disk-shaped rectifier as a whole. A plurality of commutator pieces (mainly carbon fired products) having a surface, a plurality of metal pieces individually joined to each commutator piece, and a commutator piece-metal piece while exposing a commutation surface of the commutator piece And a resin-made boss portion that supports each pair, and is fitted on a rotating shaft.
[0003]
Regarding the joining of the commutator piece and the metal piece described above, the anti-rectifying surface joining structure in which the metal piece is joined to the anti-rectifying surface side of the commutator piece, and the outside in which the metal piece is joined to the outer surface on the outer diameter side of the commutator piece. Side joint structures are known.
[0004]
However, with the anti-rectifying surface joining method, simply bonding mechanically, the joining property between the end face on the anti-rectifying surface side of the commutator piece and the flat surface of the metal piece is poor due to the spring back of the metal piece, etc. However, it is necessary to join the two together by soldering or other fusion bonding techniques while strongly pressing them in the axial direction, and an example of fusion bonding between a carbon commutator piece and a metal piece has been proposed (Japanese Patent Laid-Open No. 5-30170). ) However, considering that heat is generated when the coil conductor is joined by fusing to the terminal part of the metal piece in the subsequent process, the solder and the like that have been joined in the melt joining are melted by the heat, There was a problem that the yield decreased, and it was not suitable for mass production.
[0005]
In order to solve this problem, Japanese Patent Application Laid-Open No. 10-4653 discloses a disc-type commutator having an anti-rectifying surface junction structure, and a protrusion is provided in the axial direction on the end surface of the commutator piece on the side of the anti-rectifying surface. The hole of the metal piece is fitted and the periphery of the hole of the metal piece is deformed to prevent relative displacement in the axial direction of the both, and good electrical contact between the commutator piece and the metal piece can be achieved without the above-mentioned fusion bonding. I am trying. This publication also describes a configuration in which the protrusion is press-fitted into the hole as an example of a configuration in which the protrusion and the hole are integrated with each other.
[0006]
[Problems to be solved by the invention]
However, in the commutator piece-metal piece connection method of the above-mentioned publication, a cylindrical caulking tool having a plurality of notch protrusions at the tip is pushed around the hole of the metal piece, thereby the metal around the protrusion of the commutator piece. Cut the piece and plastically deform the vicinity of the hole of the metal piece to the hole side, thereby substantially reducing the diameter of the hole and strengthening the contact between the protrusion of the metal piece and the periphery of the hole of the metal piece. The metal piece is prevented from being displaced toward the axial anti-commutator piece side.
[0007]
This caused the following problems.
[0008]
First, it is not easy to control the depth of the above-described incision, or the thickness and the amount of inclining of the incision piece that falls to the projecting side due to the incision and comes into close contact with the projecting part.
[0009]
In addition, it is necessary to align the axial center position of the caulking tool and the center of the hole of the metal piece with high accuracy. If they are shifted, some of the plurality of cut pieces become thin, and at a position 180 degrees opposite to that, The cut piece becomes thick, and as a result, the gap between the protrusion and the hole is in a state where it is difficult to ensure electrical or mechanical contact.
[0010]
Similarly, the dimensional accuracy, formation position accuracy, and relative position accuracy during insertion of the metal piece holes and commutator piece protrusions have to be secured particularly in the radial direction. If these precisions are inferior, a part of the contact surface between the hole and the projection becomes poor in contact, and the electrical resistance of the contact portion increases, or the brittle projection is damaged.
[0011]
In addition, in the configuration that is simply press-fitted, it is only possible to engage and integrate, and if there is a variation in the position of the protrusion and the hole, a gap is generated between the inner peripheral surface of the hole and the protrusion, and conduction and fixing are performed. There is a problem that quality cannot be ensured. In the commutator piece provided with a plurality of protrusions, the above-described problem is particularly important because the positions of the protrusions and the positions of the holes are likely to vary.
[0012]
The present invention has been made in view of the above problems, and suppresses complication of the structure and the manufacturing process, prevents damage to the commutator piece, and provides good electrical and mechanical contact between the commutator piece and the metal piece. It is an object of the present invention to provide a commutator, a commutator manufacturing method, and a fuel pump.
[0013]
[Means for Solving the Problems]
  The commutator according to claim 1.Manufacturing methodIs a plurality of commutator pieces that are radially arranged around the shaft center with a predetermined gap therebetween and have a generally disc-shaped commutation surface as a whole and containing a carbon fired product. A boss portion made of resin that supports and protects each commutator piece while exposing the commutation surface in contact with the surface of the commutator, and a commutator piece connection joined to the surface of the commutator piece on the side opposite to the commutation surface And a plurality of metal pieces each having a terminal portion that extends along the outer peripheral surface of the main portion of the boss portion and to which the winding is joined from an end portion on the outer diameter side of the commutator piece connecting portion. The commutator piece has a substrate portion having the rectification surface, and a protrusion protruding from the surface of the substrate portion on the side opposite to the rectification surface, and the commutator piece connection portion of each metal piece is In a method of manufacturing a commutator having holes into which the protrusions are inserted, respectively The entire surface of the projected contact area of the protrusion, which is an area that is to be in contact with the hole after the insertion of the protrusion into the hole, is formed larger in diameter than the hole before the insertion. The part of the piece facing the hole shaves the outer peripheral surface of the protrusion.Then, facing the outer peripheral surface of the base end portion of the protrusion, a pocket is formed between the base end portion and the metal piece to accommodate the shaving powder of the protrusion of the commutator piece.It is characterized by doing. In addition, shaving as used in this specification shall mean inserting while shaving a protrusion.
[0014]
That is, according to this configuration, the diameter of the protrusion (particularly, the diameter of the planned contact area that comes into contact with the inner peripheral surface of the hole after completion of insertion) is formed to be larger than the diameter of the hole over the entire surface.
[0015]
In this way, the excess portion of the protrusion is easily scraped off by the peripheral edge of the hole of the metal piece when the insert is inserted because the commutator piece is mainly made of a carbon fired product. Even when the caulking operation is not performed, the hole and the protrusion can be in good contact with each other in the planned contact area.
[0016]
When inserting (press-fitting) while shaving the protrusion into the hole, the peripheral part of the hole of the metal piece scrapes off the excess part of the protrusion and compresses the outer peripheral surface of the remaining protrusion to the inside of the diameter, This is because the outer peripheral surface of the protrusion and the inner peripheral surface of the hole can be brought into close contact by the reaction force.
[0017]
The planned contact area may be set on the entire inner peripheral surface of the hole, or may be set on a predetermined portion of the inner peripheral surface of the hole.
[0018]
In addition, according to this configuration, the reaction force (substantially centripetal direction) that the protrusion receives from the metal piece is substantially constant over the entire circumference of the protrusion, and stress during insertion is concentrated on a part of the protrusion. It is possible to prevent mechanical damage such as cracks from occurring.
[0019]
  Further, since the machining using the caulking tool as described above is not required, and the insertion and the shaving of the protrusion are performed in the same process, the manufacturing process can be simplified, and the caulking can be realized. It is also possible to prevent damage to the protrusion due to.
  And since the cutting powder produced when the hole cuts the side surface portion (circumferential surface portion) of the protrusion at the time of insertion can be accommodated in this pocket, the cutting powder is placed between the substrate portion of the commutator piece and the metal piece. It can suppress that the electrical contact with the board | substrate part of a commutator piece and a metal piece (its commutator piece connection part) falls.
[0020]
  Claim 2A method of manufacturing a commutator includes a plurality of commutator pieces that are radially arranged around an axial center with a predetermined gap between each other and have a substantially disc-shaped commutation surface as a whole and including a carbon fired product. Resin boss part that supports and protects each commutator piece while being in contact with the surface on the side opposite to the commutation surface and exposing the current commutation surface, and is joined to the surface on the side opposite to the commutation surface of the commutator piece. A commutator piece connecting portion, and a terminal portion extending from an outer end of the commutator piece connecting portion along the outer peripheral surface of the main portion of the boss portion to which a winding is joined. A plurality of metal pieces, and the commutator piece has a substrate portion having the rectifying surface, and a protrusion protruding from a surface of the substrate portion on the side opposite to the rectifying surface, and the rectification of each metal piece The piece connecting portion has commutators each having a hole into which the protrusion is inserted. In the manufacturing method,Prior to the insertion, the commutator pieces are integrally formed to form a commutator piece, and the metal pieces are formed integrally to form a metal piece. Manufacturing tolerances of the diameter of each protrusion and the central position of the radial protrusion, manufacturing tolerances of the diameter of each hole and the central position of the radial hole in each metal piece integrated object, and the commutator piece integrated object and the metal piece integrated The projected contact area of the protrusion is determined by the sum of the radial position variations between the outer peripheral surface of the protrusion and the inner peripheral surface of the hole, which is the sum of the radial alignment tolerances with the object. Formed larger than the hole before insertionThen, after the insertion of the projection into the hole, the entire surface of the projected contact area of the projection, which is a region scheduled to contact the hole, is formed larger in diameter than the hole before the insertion, The part of the metal piece facing the hole shaves the outer peripheral surface of the protrusion.It is characterized by that.
[0021]
  According to this configuration, since the manufacturing tolerance of the radial position between the protrusion and the hole before insertion and the manufacturing tolerance of the diameter of the hole and the protrusion can be increased, the contact resistance between the hole and the protrusion is increased. The manufacturing process can be remarkably facilitated without incurring.In addition, since the shavings generated by the holes scraping the side surfaces (circumferential surface portions) of the protrusions during insertion can be accommodated in this pocket, the shavings are placed between the substrate portion of the commutator piece and the metal piece. It can suppress that the electrical contact with the board | substrate part of a commutator piece and a metal piece (its commutator piece connection part) falls.
[0022]
  According to the method for manufacturing a commutator according to claim 3,By selecting a numerical range of 3% or more of the diameter of the hole, the present inventor can improve the contact between the protrusion and the metal piece (hole) to reduce the electric resistance value and improve the mechanical strength. It was found from these experiments.
[0023]
  According to the method for manufacturing a commutator according to claim 4,By further shaving the size of the “draft surface” formed in the hole by punching with a press, the desired amount suitable for shaving the outer peripheral surface of the protrusion can be easily obtained.
[0024]
  According to the commutator according to claim 5, since the outer peripheral surface of the protrusion that contacts the inner peripheral surface of the hole is a scraped surface of the carbon fired product formed on the inner peripheral surface of the hole, The outer peripheral surface is in close contact with and in contact with the inner peripheral surface of the hole by the scraped reaction force. Thereby, a commutator having good electrical and mechanical contact can be realized.In addition, since the shavings generated by the holes scraping the side surfaces (circumferential surface portions) of the protrusions during insertion can be accommodated in this pocket, the shavings are placed between the substrate portion of the commutator piece and the metal piece. It can suppress that the electrical contact with the board | substrate part of a commutator piece and a metal piece (its commutator piece connection part) falls.
[0025]
By the way, the cutting surface is a surface shape in which the particles forming the protrusion are peeled off by inserting the protrusion into the hole. On the other hand, in the press-fitting, the particles forming the protrusion are entirely formed. It is crushed by and is different from the shaving surface here.
[0026]
According to Claim 6, the substantially flat surface of the metal piece facing the inner peripheral surface of the hole extending in the axial direction and the anti-rectifying surface of the commutator piece extending in the radial direction. The peripheral corner portion composed of the intersecting region with the edge has a rounded chamfered portion or a press sagging portion, and the chamfering amount or the press sagging amount is determined from the intersection of the inner peripheral surface and the flat surface with the inner peripheral surface. It is characterized by being in a region of 0.2 mm or less in the direction and radial direction.
[0027]
Furthermore, the present inventor has found through experiments that the cracks and breaks of the protrusions during shaving can be reduced as the roundness of the peripheral corner portion, which is the flat surface portion on the commutator piece side of the metal piece surrounding the hole, is reduced. Further, the present inventor can prevent the protrusion from cracking if the roundness is suppressed to 0.2 mm or less from the ideal intersection of the inner circumferential surface and the flat surface where the rounding is zero to the inner circumferential surface direction and the radial direction. It was found through experiments that damage can be reduced.
[0028]
According to the seventh aspect, the electric resistance value can be set to a desired value in the fastening by shaving.
[0029]
According to the description of claim 8, a desired electric resistance value can be obtained more easily.
[0031]
  Claim9According to the description, when forming a metal piece from a metal flat plate by press working, the gap formed in the peripheral portion of the hole or the gap adjacent to the chamfered portion processed by the press constitutes the pocket. Therefore, it is not necessary to perform complicated shape processing on the commutator piece forming mold or the metal piece processing mold, and the manufacturing cost can be reduced.
[0032]
  Claim10According to the description, even if the hole and the protrusion are displaced, it is possible to reduce the gap formed between the inner peripheral surface of the hole and the protrusion and increase the axial distance of the closely contacting portion. Therefore, good and easy electrical and mechanical connection can be ensured.
[0033]
  Claim11According to the description, it becomes easy to mold the protrusion and insert the protrusion into the hole.
[0034]
  Claim12According to the description, the contact area between the hole and the protrusion can be increased, and the compressive force applied to the protrusion by the hole at the time of shaving insertion can be increased, so that the contact electrical resistance of both can be further reduced. .
[0035]
  AlsoThe concave portion constitutes the pocket for accommodating the cutting powder generated by cutting the side surface portion (circumferential surface portion) of the protrusion during insertion, so that the cutting powder is formed between the substrate portion of the commutator piece and the metal piece. It can suppress that the electrical contact of the board | substrate part of a commutator piece and a metal piece (its commutator piece connection part) falls by interposing.
[0036]
  Claim13According to the description, it is possible to improve the durability of the commutator of the DC motor-integrated fuel pump that boosts the fuel containing sulfur as an impurity.
[0037]
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the invention are illustrated by the following examples. Of course, the form of the present invention is not limited to the following examples.
[0038]
[Example 1]
The commutator of this embodiment will be described with reference to FIG.
[0039]
(Overall structure)
This commutator is composed of a commutator piece 1, a metal piece 2, and a boss 3, and is mounted on a motor integrated with a fuel pump.
[0040]
A plurality of commutator pieces 1 are provided, and each commutator piece 1 is radially arranged around the shaft center with a predetermined gap in the circumferential direction and is formed by sintering, and the ring plate as a whole. A straightening current surface 10 is provided. The commutator piece 1 has a surface portion 11 made of carbon powder and a back side portion 12 made of a mixed powder of metal powder (for example, copper powder) and carbon powder provided on the side of the surface portion 11 opposite to the rectifying surface. And a projecting portion 13 made of a mixed powder of metal powder (for example, copper powder) and carbon powder that protrudes from the back side portion 12 toward the axially anti-rectifying surface side. With this metal powder, the specific resistance of the protrusion 13 is 3000 μΩ · cm or less.
[0041]
A plurality of metal pieces 2 are provided and will be described later from a commutator piece connection portion 21 that is individually joined to the surface of the back side portion 12 on the side opposite to the rectifying surface, and an end portion outside the diameter of the commutator piece connection portion 21. An axially extending portion 22 that extends in the axial direction along the outer peripheral surface of the boss portion 3, protrudes from the end on the non-rectifying surface side of the axially extending portion 22 to the radially outer side and the commutator piece 1 side, not shown. The armature coil has a terminal portion 23 to which the tip of the armature coil is connected by fusing.
[0042]
The boss 3 is formed of a resin into a thick disc shape, and has a shaft hole 30 at the radial center. Further, the boss portion 3 covers a portion of the surface of the commutator piece connecting portion 21 of the metal piece 2 that is not joined to the commutator piece 1. Further, the boss portion 3 covers the surface of each commutator piece 1 except for the commutation surface and the circumferential side surface of each commutator piece 1.
[0043]
The commutator piece connecting portion 21 of the metal piece 2 has a hole 4, the protrusion 13 of the commutator piece 1 is fitted into the hole 4, and the protrusion 13 has an outer peripheral surface 132 in the axial direction of the protrusion. The shaving surface 132 a occupying most is in close contact with the inner peripheral surface 41 of the hole 4. At the same time, the upper surface of the commutator piece connecting portion 21 in FIG. 1 is in close contact with the surface on the side opposite to the rectifying surface of the back side portion 12 of the commutator piece 1, and in combination with the metal powder placed in the back side portion 12. Good electrical contact is ensured. The commutator piece 1 and the metal piece 2 can be thermally bonded.
[0044]
(Production method)
First, each commutator piece 1 is pressed into a shape in which each of the commutator pieces 1 is precisely formed by carbon sintering and is substantially in the shape of an annular plate and each metal piece 2 is integrated into a predetermined shape by a connecting portion. A metal plate produced by processing is prepared (see FIG. 2).
[0045]
The diameter of the protrusion 13 is made larger by a predetermined dimension L than the diameter of the hole 4. The peripheral edge of the top surface 14 of the protrusion 13 is chamfered, and the diameter of the top surface 14 is smaller than that of the hole 4. Although this will be described later, this is for facilitating the insertion of the protrusion 13 into the hole 4. Furthermore, it is for maintaining good electrical and mechanical connection even with respect to the positional deviation between the protrusion 14 and the hole 4. Further, the back side portion 12 of the commutator piece 1 has a ring-shaped recess 15 surrounding the base portion of the protrusion 13 while being in contact therewith. The concave portion 15 forms a pocket for housing the shavings as referred to in the present invention.
[0046]
This will be described in more detail with reference to FIG.
[0047]
In this embodiment, the peripheral corner portion 130 where the top surface 14 of the protrusion 13 of the commutator piece 1 and the outer peripheral surface (side surface) 140 intersect is gently chamfered over the entire periphery, and the peripheral corner tapered surface 130 is formed. Yes.
[0048]
Since the peripheral corner taper surface 130 of the protrusion 13 is chamfered, all the top surfaces 14 of the protrusion 13 enter the hole 4 at the start of press-fitting, and the peripheral corner 210 of the hole 4 is the peripheral edge of the protrusion 13. The corner taper surface 130 is abutted obliquely. This is advantageous for applying a radial compressive force from the peripheral corner 210 of the hole 4 to the peripheral corner taper surface 130 of the protrusion 13.
[0049]
Accordingly, when the sum of the manufacturing tolerances of both members and the relative alignment error (diameter direction) at the time of press-fitting is adjusted to a predetermined allowable value or less, the peripheral corner taper surface 130 of the protrusion 13 is always the peripheral angle of the hole 4. The shaving fastening allowance, the inner diameter and the outer diameter of the peripheral corner taper surface 130 are set so as to contact the portion 210 and secure a suitable shaving fastening allowance.
[0050]
Thereby, if the total of the manufacturing tolerance of both members and the relative alignment error (diameter direction) at the time of press-fitting is equal to or less than a predetermined allowable value, a suitable coupling can be achieved.
[0051]
Further, since the peripheral corner taper surface 130 is chamfered with a gentle taper surface, the protrusion 13 is inserted into the hole 4 with respect to the positional deviation between the commutator piece connection portion 21 and the protrusion 13. The volume to be produced can be made larger. That is, even if the positional deviation is large, it is possible to prevent a gap from being formed between the hole 4 and the protrusion 13, and it is possible to easily prevent a decrease in electrical and mechanical connection due to this.
[0052]
In FIG. 22, the outer peripheral surface 140 of the protrusion 13 is a tapered taper surface. That is, the protrusion 13 is formed in a truncated cone shape. This facilitates the extraction of the protrusion 13 from the mold after sintering.
[0053]
Next, the protrusion 13 protruding from the end face of the disk on the side opposite to the rectifying surface is press-fitted into the hole 4 of the commutator piece connecting portion 21 of each metal piece 2. Since the protrusion 13 is a sintered body containing carbon powder as a main component, it is fragile. As a result, the portion of the protrusion 13 that does not completely enter the hole 4 is formed in the hole 4 of the commutator piece connecting portion 21 during the press-fitting. It is scraped off by the peripheral edge and peeled off from the protrusion 13 and is almost accommodated in the recess 15 by being pushed by the commutator piece connecting portion 21 or by gravity.
[0054]
This state is shown in FIG.
[0055]
The head 131 of the protrusion 13 protrudes from the end face 212 on the side opposite to the commutator piece 21 of the commutator piece connection part 21. The head 131 is formed by a portion of the peripheral corner taper surface 130 that remains without being scraped by the peripheral corner 210 of the hole 4 and the top surface 14.
[0056]
In particular, in this embodiment, the head 131 protrudes from the end face 212 on one side of the anti-commutator, so that the inner peripheral surface 4 of the hole 4 and the outer peripheral surface 132 of the protrusion 13 extend over the entire axial length of the protrusion 13. Good adhesion.
[0057]
This is because the tapered surface 130 is gentle. When the tapered surface 130 is steep, if the hole 14 and the protrusion 13 are misaligned, the inner peripheral surface 41 and the protrusion 13 A gap is formed between them, and the contact length in the axial direction is reduced.
[0058]
When the press-fitting is completed, the upper surface of the commutator piece connection portion 21 of the metal piece 2 is in close contact with the lower surface of the back side portion 12 in FIG. 1, and the outer peripheral surface of the protrusion 13 is the inner peripheral surface of the hole 4. In addition, the pressure force is closer to the reaction force of the compressive force acting on the protrusion 13 during the press-fitting.
[0059]
Next, this integrated product is set in a mold, and the boss portion 3 is molded by resin insert molding or resin mold molding. Thereby, the commutator piece connecting portion 21 of the metal piece 2 is embedded in the boss portion 3, and the axially extending portion 23 of the metal piece 2 is in close contact with the outer surface of the boss portion 3 and extends in the axial direction. .
[0060]
Next, the disk is cut radially from the rectifying surface 10 side to a predetermined depth by a rotating disk blade to form a plurality of slits, and the disk is divided into a predetermined number of commutator pieces 1 and at the same time, each metal piece 2 The above-mentioned connecting portion connecting the two is also cut to divide each metal piece 2.
[0061]
Finally, a copper wire is joined to the terminal portion 23 of the metal piece 2 by a fusing process.
[0062]
According to the commutator of this embodiment described above and its manufacturing method,
Good electrical contact between the commutator piece and the metal piece in the disc-type commutator of the anti-rectifying surface junction structure without complicating the structure and manufacturing process and without increasing the damage probability of the commutator piece. Can be realized.
[0063]
Other features of the commutator of this embodiment will be described below.
[0064]
First, the diameter of the protrusion 13 (particularly, the diameter of a planned contact area that contacts the inner peripheral surface of the hole 4 after completion of insertion) is formed to be larger than the diameter of the hole 4 over the entire surface. The planned contact area here refers to the area of the outer peripheral surface of the protrusion 13 that faces the inner peripheral surface of the hole 4 in the radial direction after being scraped by the hole 4.
[0065]
In this way, the excess portion of the protrusion 13 is easily scraped by the peripheral edge of the hole of the metal piece because the commutator piece has a brittle characteristic mainly made of carbon fired material, and as a result, the protrusion The part 13 can be in good contact with the hole 4. This is because when the protrusion 13 is inserted (press-fitted) into the hole 4, the peripheral edge of the hole 4 cuts off the excess portion of the protrusion 13 and compresses the outer peripheral surface of the remaining protrusion 13 to the inside of the diameter. This is because, of the outer peripheral surface 132 of the protrusion 13, the contact surface 132 a and the inner peripheral surface of the hole 4 are in good contact with each other by the reaction force. The outer peripheral surface 132 is a shaving surface referred to in the present invention, and the contact surface 132a is also a shaving surface. That is, the particles forming the protrusions are peeled off.
[0066]
Next, the mechanical force that the protrusion 13 receives from the hole 4 at the time of insertion is substantially constant over the entire circumference of the protrusion 13, and stress during insertion is not concentrated on a part of the protrusion 13. The occurrence of mechanical damage to the portion 13 can also be suppressed.
[0067]
Next, in this embodiment, the manufacturing tolerance of the diameter and position of each protrusion 13 in the disk, that is, each commutator piece, and the diameter and position of each hole 4 in the metal plate, that is, each metal piece, are manufactured. The diameter immediately before press-fitting between the outer peripheral surface of the protrusion 13 and the inner peripheral surface of the hole 4, which is the sum of the tolerance and the radial alignment tolerance between the commutator piece integral and the metal piece integral. The radial dimension difference between the protrusion 13 and the hole 4 in the planned contact area of the protrusion 13 is set larger than the sum of the directional position variations. Thereby, even if the manufacturing tolerance and the alignment tolerance (alignment error margin expected in advance in manufacturing) are set large, the protrusion 13 and the hole 4 can be in close contact with each other over the entire planned contact area, The above effects can be ensured while simplifying the manufacturing process.
[0068]
Next, in this embodiment, the metal piece integrated body before dividing is produced by stamping a metal flat plate from one side in the thickness direction to the other side. At this time, the commutator piece connection of the metal piece 2 is performed. The peripheral edge of the other side of the hole 4 of the portion 21 is pushed and bent in the punching direction to form a so-called burr. For this reason, one side of the peripheral edge portion of the hole 4 of the commutator piece connecting portion 21 is a bent portion (so-called drooping portion or drooping portion) that drops toward the hole 4. In this embodiment, the protrusion 13 is inserted into the hole 4 from the bent portion side. If it does in this way, the efficiency of the operation | work which inserts without a crack can be improved, and also the amount of shavings accommodation of the said pocket, ie, the recessed part 15, can be increased by the part which this accompanying bending part is dented. When the amount of planned cutting powder is small, the recess 15 may be omitted, and a space between the bent portion of the commutator piece connecting portion 21 and the substrate portion 12 of the commutator piece 1 may be used as a pocket. . Moreover, you may provide this pocket in the peripheral part of the hole 4 of the metal piece 2 instead of the commutator piece 1 side.
[0069]
When the hole 4 is normally punched, a dripping of about 10% of the thickness (also referred to as sagging) occurs. Therefore, if the amount of dripping is large, a crack occurs in the protrusion when the shaving is pressed. In order to prevent this, the metal piece 2 is further processed into a seabing hole after punching, whereby the drooping amount can be easily set to a desired amount suitable for shaving the outer peripheral surface of the protrusion. In this embodiment, the thickness of the metal piece is 1 mm, and the shaving hole is processed after punching. Here, the shaving hole processing means that a part of the sloping surface on the inner periphery of the hole is scraped to reduce the size in the axial direction.
[0070]
[Example 2]
Another embodiment of the present invention will be described with reference to FIGS. However, the commutator piece 1 and the metal piece 2 indicate parts other than the important part.
[0071]
In this embodiment, the outer peripheral surface of the protrusion 13 of the commutator piece 1 is formed with eight groove portions extending in the axial direction at a predetermined pitch in the circumferential direction, and two arbitrary groove portions adjacent in the circumferential direction are formed. In the middle, ridges extending in the axial direction are formed. The diameter from the center line of the protrusion 13 to the groove bottom surface of the groove is formed smaller than the diameter of the hole 4 of the metal piece 2, and the diameter from the center line of the protrusion 13 to the top surface of the protrusion is The diameter of the hole 4 of the metal piece 2 is larger. Thereby, when inserting the protrusion 13 in the hole 4, the vicinity of the top surface of the protrusion of the protrusion 13 is scraped, and both come into close contact (see FIG. 8). Further, a space (pocket) is formed between the inner peripheral surface of the hole 4 of the metal piece 2 and the above-mentioned groove portion of the protrusion 13 to accommodate the scraped carbon powder.
[0072]
[Example 3]
Another embodiment of the present invention will be described with reference to FIGS. However, the commutator piece 1 and the metal piece 2 indicate parts other than the important part.
[0073]
In this embodiment, contrary to the embodiment 2, the inner peripheral surface of the hole 4 of the metal piece 2 is formed with eight groove portions extending in the axial direction at a predetermined pitch in the circumferential direction, and any arbitrary adjacent in the circumferential direction. Between the two groove portions, projecting ridge portions each extending in the axial direction are formed. The diameter from the center line of the hole 4 to the groove bottom surface of the groove is formed larger than the diameter of the protrusion 13, and the diameter from the center line of the hole 4 to the top surface of the protrusion is It is formed smaller than the diameter. Thereby, when inserting the protrusion 13 in the hole 4, the said protrusion part of the metal piece 2 which faces the hole 4 scrapes the outer peripheral surface of the protrusion 13, and both contact closely (refer FIG. 13). Further, a space (pocket) is formed between the groove portion of the hole 4 of the metal piece 2 and the outer peripheral surface of the protrusion 13 to accommodate the scraped carbon powder.
[0074]
[Example 4]
Another embodiment of the present invention will be described with reference to FIG. However, the commutator piece 1 and the metal piece 2 indicate parts other than the important part.
[0075]
In this embodiment, the commutator piece connecting portion 21 of the metal piece 2 includes eight ridge portions (small projections) 41 extending in the axial direction on the inner peripheral surface of the hole 40, and adjacent ridge portions 41, The point which has the eight recessed parts 42 formed between 41 differs from the hole 4 of Example 1. FIG. In this embodiment, the protrusion 13 press-fitted into the hole 40 is in contact with the surface of the protrusion (small protrusion) 41 and the recess 42 over the entire circumference. If it does in this way, the contact area of the protrusion 13 and the hole 40 can be further earned, and both contact resistance can be reduced further. In addition, many holes 4 and 40 provided in the commutator piece connection part 21 of the metal piece 2 may be provided, and the shape is free.
[0076]
[Example 5]
Another embodiment will be described below with reference to FIG.
[0077]
FIG. 15 shows the relationship between the pulling force (fastening force) required to pull out the protrusion 13 from the hole 4 and the shaving fastening allowance (pulling force / shaving fastening allowance characteristics), and FIG. 16 shows the shaving fastening allowance and shaving (shaving). The relationship with allowance and elasticity allowance is shown.
[0078]
The shaving fastening allowance refers to the sum of the shaving (shaving) allowance and the elastic allowance. The shaving allowance refers to the protrusion 13 having a diameter made larger than the inner diameter of the hole 4 by a predetermined value or more. Means the outer peripheral portion of the protrusion 13 that is not cut into the hole 4 when it is press-fitted into the hole, and the elastic margin means the amount of radial contraction when the press-fitted protrusion 13 is elastically compressed in the radial direction. .
[0079]
The radial contraction amount (elasticity allowance) of the protrusion 13 should have a correlation with the extraction force required to extract the protrusion 13 from the hole 4. That is, the generated frictional force (pulling force) at the time of pulling out should be approximately proportional to the product of the contact area, the friction coefficient, and the compressive force, and the pulling force is approximately proportional to the compressive force. It is possible to determine the strength of mechanical coupling between the metal piece 2 and the metal piece 2.
[0080]
As can be seen from FIG. 15, the shaving fastening allowance and the pulling force (and hence the compressive force, and eventually the elastic allowance) increase in proportion to the increase in the shaving fastening allowance, but have a certain value (in FIG. 15, the shaving fastening allowance). However, the pulling force reaches a peak value at 3% of the hole diameter, and thereafter the pulling force does not increase and slightly decreases even if the shaving fastening allowance is increased.
[0081]
From the above experiment, it is understood that the peak value of the pulling force can be obtained by setting the shaving fastening allowance to 3% or more of the hole diameter, and that a good mechanical connection between the protrusion 13 and the hole 4 and a low electric resistance value can be realized. It was.
[0082]
FIG. 17 shows the relationship between the electrical resistance value of the protrusion 13 and the metal piece 2 and the shaving fastening allowance under the same experimental conditions as in FIGS. 15 and 16. It can be seen from FIG. 17 that the electrical resistance value has a characteristic that is very similar to the reciprocal of the elastic margin. Therefore, the electrical resistance value / shaving fastening allowance characteristic indicating the relationship between the electrical resistance value and the shaving fastening allowance is obtained in advance by experiment, and the shaving fastening allowance is set within a range where the electrical resistance value is less than the desired value. A low electrical resistance value and good coupling can be realized.
[0083]
Also, from FIG. 16, an elastic allowance / shaving allowance characteristic or an elastic allowance / shaving fastening allowance characteristic indicating a relationship between the elastic allowance and the shaving allowance or the shaving fastening allowance is obtained in advance by experiment, and the elastic allowance is determined on this characteristic. Even if the shaving fastening allowance is determined so as to be equal to or greater than the desired value, a low electrical resistance value and good coupling can be realized.
[0084]
It is preferable to provide a plurality of holes 4 in the commutator piece connecting portion 21 of the metal piece 2 and to provide a plurality of protrusions 13 in the commutator piece 1. Due to tolerance variations, the protrusion 13 may be displaced in the radial direction with respect to the hole 4 and the initial shaving fastening allowance may not be obtained.
[0085]
It is desirable that the sum of 3% of hole diameter variation, protrusion diameter variation, hole misalignment, protrusion misalignment, and hole diameter is less than or equal to the shaving fastening allowance.
[0086]
(Modification)
In addition, a plurality of protrusions 13 are provided on a carbon disk made of a carbon fired product, a plurality of holes 4 are provided in a metal disk, and each protrusion 13 is press-fitted individually into each hole 4 so that the carbon disk and the metal circle are A predetermined number of pieces are radially cut to form a commutator piece 1 from a carbon disk and a metal piece 2 from a metal circle. Therefore, in this case, shaving fastening is performed so that the shaving fastening allowance is still a suitable value even if the sum of manufacturing tolerances and alignment errors between each protrusion 13 of the carbon disk and each hole 4 of the metal disk are taken into account. The set value of the bill is determined. In this case, each divided commutator piece 1 has one to a plurality of protrusions 13, and each divided metal piece 2 can have one to a plurality of holes 4. If the sum of manufacturing tolerances of each member and the sum of relative alignment errors at the time of press-fitting are equal to or less than a predetermined allowable maximum value, a shaving fastening allowance is obtained so that a suitable shaving fastening allowance is obtained over the entire circumference of each protrusion 13. And if the allowable value of the sum of the manufacturing tolerance (variation of member dimensions) and the sum of the relative alignment errors at the time of press-fitting is set, a low electrical resistance value and a good mechanical coupling can be realized.
[0087]
[Example 6]
Another embodiment will be described below with reference to FIG.
[0088]
The shaving during the press-fitting of the protrusion 13 is related to the shape of the peripheral corner 210 of the commutator piece connecting portion 21 surrounding the hole 4. In addition, this peripheral corner | angular part exists in the opening end of the hole 4 by the side of the commutator piece 1 of the commutator piece connection part 21 naturally. That is, if the dent of the peripheral corner portion 210 is small and sharp, the shaving is good, and the protrusion 13 does not crack during shaving.
[0089]
Under the same conditions as the experiments of FIGS. 15 to 17, the peripheral corner portion 210 of the hole 4 is 45 degrees with respect to the inner peripheral surface 400 and the flat surface 401 of the commutator piece connecting portion 21 as shown in FIG. 18. The relationship between the size (dent amount) of the peripheral corner 210 when chamfering at a flat angle and the damage state of the protrusion 13 during press-fitting was examined. The result is shown in FIG. From FIG. 19, it can be seen that if A = B is less than 0.2 mm, shaving and press-fitting can be performed without damage to the protrusion 13. When A = B = 0.2 mm, cracks occur regardless of the shaving fastening allowance, so at least one of the dimensions A and B needs to be less than 0.2 mm.
[0090]
As shown in FIG. 20, the peripheral corner portion 210 may be formed by a press droop portion 2100 when the hole 4 is punched out by press working, and the inner peripheral surface 400 is chamfered by shaving hole processing after press forming. You may form by value.
[0091]
[Example 7]
FIG. 23 shows an overall configuration of a vehicle DC motor integrated fuel pump to which the commutator described above is applied, and FIG. 24 is an enlarged view of the commutator portion.
[0092]
A DC motor 501 is built in the casing 500, and the DC motor 501 includes a stator 5011, an armature 5012, a rotating shaft 5013, a commutator 5014, and a brush 5015. Reference numerals 5016 and 5017 denote bearings.
[0093]
One end portion of the rotary shaft 5013 projects through the partition wall 5001 that separates the pump 600 and the DC motor 501 in the axial direction, and protrudes toward the pump 600. The rotary blade 601 of the pump 600 is provided at one end portion of the rotary shaft 5013. It has been. Reference numeral 602 denotes a fuel discharge port, and the fuel intake port is not shown. The commutator 5014 is fixed to the other end of the rotating shaft 5013 adjacent to the armature 5012, and the brush 5015 is in sliding contact with the commutator 5014.
[0094]
Since the configuration and operation of this type of DC motor integrated fuel pump for vehicles are well known, further detailed description is omitted.
[0095]
According to this embodiment, the durability of the commutator of the vehicular DC motor integrated fuel pump for boosting the fuel containing sulfur as an impurity, particularly the durability of the protrusion 13 of the commutator piece 1 is improved. Lifespan can be improved.
[0096]
(Modification)
In the embodiment, by selectively mixing metal powder such as copper powder into the protrusion 13, the resistance loss of the protrusion 13 where current concentrates is further reduced. In addition, the specific resistance of the protrusion 13 may be 3000 μΩ · cm or less by the low resistance carbon layer.
[0097]
(Modification)
In the above-described embodiment, the carbon disk protrusion 13 is press-fitted into the hole 4 of the metal disk, and then the metal disk / carbon disk integrated object is radiated and cut, but one or both of them are radiated and cut in advance before the press-fitting. It is also possible.
[0098]
(Modification)
In the above embodiment, the commutator has a disc-shaped commutation surface, but the commutation surface may be formed in a cylindrical surface.
[0099]
Note that the manufacturing tolerances (dimensional tolerance variations) of the members described above include pitch deviation between the holes 4, diameter variation of the holes 4, pitch deviation of the protrusions 13, and radial variations of the protrusions 13.
[0100]
(Modification)
In the said Example, although it forms in the edge part of the plate | board thickness direction which a drooping surface has, as shown to FIG. 25, FIG. 26, it is located in the opening part of the hole 4a, and a commutator piece connection part 21a has a large diameter. A disk-shaped concave portion may be formed, and a sagging surface may be formed at the boundary portion of the hole 4a in contact with the disk-shaped concave portion.
[Brief description of the drawings]
FIG. 1 is an axial half sectional view of a commutator according to a first embodiment.
FIG. 2 is a schematic cross-sectional view showing an alignment state before press-fitting of the commutator according to the first embodiment.
3 is a schematic cross-sectional view showing a state after the press-fitting of the commutator of Example 1. FIG.
4 is a plan view of a metal piece of Example 2. FIG.
5 is a sectional view in the thickness direction of Example 2. FIG.
FIG. 6 is a plan view of a commutator piece according to a second embodiment.
7 is a sectional view in the thickness direction of a commutator piece of Example 2. FIG.
FIG. 8 is a cross-sectional view showing a fitting state between a commutator piece and a metal piece of Example 2.
9 is a plan view of a metal piece of Example 3. FIG.
10 is a sectional view in the thickness direction of Example 3. FIG.
FIG. 11 is a plan view of a commutator piece according to a third embodiment.
12 is a cross-sectional view in the thickness direction of a commutator piece of Example 3. FIG.
13 is a cross-sectional view showing a fitted state between a commutator piece and a metal piece of Example 3. FIG.
14 is a cross-sectional view showing a fitting state between a commutator piece and a metal piece of Example 4. FIG.
FIG. 15 is a characteristic diagram showing a pulling force / shaving fastening allowance characteristic;
FIG. 16 is a characteristic diagram showing a relationship between shaving allowance and elastic allowance and shaving fastening allowance.
FIG. 17 is a characteristic diagram showing a relationship between an electric resistance value and a shaving fastening allowance.
FIG. 18 is a partial axial sectional view showing a chamfered state of a peripheral corner of a metal piece.
FIG. 19 is a diagram showing a damage state of the protrusion 13 at each shaving fastening allowance by the peripheral corner portion of FIG. 18;
20 is a partial cross-sectional view in the axial direction showing an example in which the peripheral corner portion of FIG. 18 is formed by a press sagging portion.
21 is a partial axial sectional view showing an example in which the peripheral corner portion of FIG. 18 is formed by shaving.
FIG. 22 is an axial sectional view showing a protrusion having a chamfered peripheral corner.
FIG. 23 is an overall configuration diagram of a fuel pump.
24 is an enlarged view of the vicinity of the commutator in FIG. 23. FIG.
FIG. 25 is an axial partial cross-sectional view showing a modified embodiment in which a peripheral corner portion is formed by a press sagging portion.
FIG. 26 is a partial axial cross-sectional view showing a modified embodiment in which a peripheral corner is formed by shaving.
[Explanation of symbols]
1 Commutator piece
2 Metal pieces
3 Boss
4 holes
13 Projection
15 pockets
21 Commutator piece connection

Claims (13)

互いに所定ギャップを隔てつつ軸心周囲に放射状に配置されて全体として略円盤形状の整流面を有するとともにカーボン焼成物を含む複数の整流子片、
各前記整流子片の主として反整流面側の表面に接して前記整流面を露出させつつ前記各整流子片を支持し保護する樹脂製のボス部、及び、各前記整流子片の反整流面側の表面に接合される整流子片接続部、及び、
前記整流子片接続部の径外側の端部から前記ボス部の前記主部の外周面に沿って延在して巻線が接合される端子部をそれぞれ有する複数の金属片、
を備え、
前記整流子片は、前記整流面を有する基板部、及び、前記基板部の反整流面側の表面から突出する突部を有し、
各前記金属片の前記整流子片接続部は、前記突部が挿入される孔をそれぞれ有する整流子の製造方法において、
前記孔への前記突部の挿入後にて前記孔に接する予定の領域である前記突部の予定接触領域の全面を前記挿入前にて前記孔より径大に形成し、
前記挿入に際して、前記金属片の前記孔に面する部位が前記突部の外周面をシェービングし、
前記突部の基端部の外周面に面して前記基端部と前記金属片との間に、前記整流子片の突部の削り粉を収容するポケットを形成することを特徴とする整流子の製造方法。A plurality of commutator pieces that are radially arranged around the axis center with a predetermined gap therebetween and have a generally disc-shaped rectifying surface as a whole and including a carbon fired product;
Resin bosses that support and protect each commutator piece while exposing the commutation surface while being in contact with the surface of the commutator piece mainly on the side opposite to the commutation surface, and the anti-commutation surface of each commutator piece Commutator piece joint joined to the surface on the side, and
A plurality of metal pieces each having terminal portions extending along the outer peripheral surface of the main portion of the boss portion from which the windings are joined from the radially outer end of the commutator piece connecting portion;
With
The commutator piece has a substrate portion having the rectifying surface, and a protrusion protruding from the surface of the substrate portion on the side opposite to the rectifying surface,
In the commutator manufacturing method, each commutator piece connecting portion of each metal piece has a hole into which the protrusion is inserted.
The entire surface of the projected contact area of the protrusion, which is an area scheduled to contact the hole after the insertion of the protrusion into the hole, is formed larger in diameter than the hole before the insertion,
During the insertion, the portion of the metal piece facing the hole shaves the outer peripheral surface of the protrusion ,
A rectifier that faces the outer peripheral surface of the base end portion of the protrusion and that forms a pocket for storing the shavings of the protrusion of the commutator piece between the base end portion and the metal piece. Child manufacturing method. 互いに所定ギャップを隔てつつ軸心周囲に放射状に配置されて全体として略円盤形状の整流面を有するとともにカーボン焼成物を含む複数の整流子片、
各前記整流子片の主として反整流面側の表面に接して前記整流面を露出させつつ前記各整流子片を支持し保護する樹脂製のボス部、及び、各前記整流子片の反整流面側の表面に接合される整流子片接続部、及び、
前記整流子片接続部の径外側の端部から前記ボス部の前記主部の外周面に沿って延在して巻線が接合される端子部をそれぞれ有する複数の金属片、
を備え、
前記整流子片は、前記整流面を有する基板部、及び、前記基板部の反整流面側の表面から突出する突部を有し、
各前記金属片の前記整流子片接続部は、前記突部が挿入される孔をそれぞれ有する整流子の製造方法において、
前記挿入前に、前記各整流子片を一体に形成して整流子片一体物とし、かつ、前記各金属片を一体に形成して金属片一体物とし、
前記各整流子片一体物における前記各突部の径及び径方向突部中心位置の製造公差と、前記各金属片一体物における前記各孔の径及び径方向孔中心位置の製造公差と、前記整流子片一体物と金属片一体物との間の径方向位置合わせ公差との合計からなる前記突部の外周面と前記孔の内周面との間の径方向位置ばらつきの総和よりも、前記突部の予定接触領域を前記挿入前にて前記孔より径大に形成し、
前記孔への前記突部の挿入後にて前記孔に接する予定の領域である前記突部の予定接触領域の全面を前記挿入前にて前記孔より径大に形成し、
前記挿入に際して、前記金属片の前記孔に面する部位が前記突部の外周面をシェービングすることを特徴とする整流子の製造方法。 A plurality of commutator pieces that are radially arranged around the axis center with a predetermined gap therebetween and have a generally disc-shaped rectifying surface as a whole and including a carbon fired product;
Resin bosses that support and protect each commutator piece while exposing the commutation surface while being in contact with the surface of the commutator piece mainly on the side opposite to the commutation surface, and the anti-commutation surface of each commutator piece Commutator piece joint joined to the surface on the side, and
A plurality of metal pieces each having terminal portions extending along the outer peripheral surface of the main portion of the boss portion from which the windings are joined from the radially outer end of the commutator piece connecting portion;
With
The commutator piece has a substrate portion having the rectifying surface, and a protrusion protruding from the surface of the substrate portion on the side opposite to the rectifying surface,
In the commutator manufacturing method, each commutator piece connecting portion of each metal piece has a hole into which the protrusion is inserted.
Before the insertion, each commutator piece is formed integrally to form a commutator piece, and each metal piece is formed integrally to form a metal piece.
Manufacturing tolerances of the diameters and radial protrusion center positions of the protrusions in the commutator piece integrals, manufacturing tolerances of the diameters and radial hole center positions of the holes in the metal piece integrals, and Rather than the sum of the radial position variations between the outer peripheral surface of the protrusion and the inner peripheral surface of the hole, which consists of the sum of the radial alignment tolerances between the commutator piece integral and the metal piece integral, The projected contact area of the protrusion is formed larger in diameter than the hole before the insertion ,
The entire surface of the projected contact area of the protrusion, which is an area scheduled to contact the hole after the insertion of the protrusion into the hole, is formed larger in diameter than the hole before the insertion,
A method of manufacturing a commutator , wherein a portion of the metal piece facing the hole shaves the outer peripheral surface of the protrusion during the insertion . 互いに所定ギャップを隔てつつ軸心周囲に放射状に配置されて全体として略円盤形状の整流面を有するとともにカーボン焼成物を含む複数の整流子片、
各前記整流子片の主として反整流面側の表面に接して前記整流面を露出させつつ前記各整流子片を支持し保護する樹脂製のボス部、及び、各前記整流子片の反整流面側の表面に接合される整流子片接続部、及び、
前記整流子片接続部の径外側の端部から前記ボス部の前記主部の外周面に沿って延在して巻線が接合される端子部をそれぞれ有する複数の金属片、
を備え、
前記整流子片は、前記整流面を有する基板部、及び、前記基板部の反整流面側の表面から突出する突部を有し、
各前記金属片の前記整流子片接続部は、前記突部が挿入される孔をそれぞれ有する整流子の製造方法において、
前記孔への前記突部の挿入後にて前記孔に接する予定の領域である前記突部の予定接触領域の全面を前記挿入前にて前記孔より径大に形成し、
前記孔の内周面に接する前記突部の外周面を前記挿入時に全周にわたって前記金属片によりシェービングするとともに、径方向に弾性圧縮された前記突部の径方向の弾性圧縮量である弾性代と、前記シェービングによる前記突部の径方向減少量として規定される前記シェービング代との合計であるシェービング締結代を、前記孔の直径の３％以上とすることを特徴とする整流子の製造方法。 A plurality of commutator pieces that are radially arranged around the axis center with a predetermined gap therebetween and have a generally disc-shaped rectifying surface as a whole and including a carbon fired product;
Resin bosses that support and protect each commutator piece while exposing the commutation surface while being in contact with the surface of the commutator piece mainly on the side opposite to the commutation surface, and the anti-commutation surface of each commutator piece Commutator piece joint joined to the surface on the side, and
A plurality of metal pieces each having terminal portions extending along the outer peripheral surface of the main portion of the boss portion from which the windings are joined from the radially outer end of the commutator piece connecting portion;
With
The commutator piece has a substrate portion having the rectifying surface, and a protrusion protruding from the surface of the substrate portion on the side opposite to the rectifying surface,
In the commutator manufacturing method, each commutator piece connecting portion of each metal piece has a hole into which the protrusion is inserted.
The entire surface of the projected contact area of the protrusion, which is an area scheduled to contact the hole after the insertion of the protrusion into the hole, is formed larger in diameter than the hole before the insertion,
The outer peripheral surface of the protrusion that is in contact with the inner peripheral surface of the hole is shaved by the metal piece over the entire circumference during the insertion , and is an elastic margin that is the amount of elastic compression in the radial direction of the protrusion that is elastically compressed in the radial direction. And a shaving fastening allowance, which is a sum of the shaving allowances defined as the radial reduction amount of the protrusion by the shaving, is 3% or more of the diameter of the hole, . 請求項１から３のいずれか一項に記載の整流子の製造方法において、
前記金属片の孔をプレスにて打ち抜き形成し、その後、前記孔の内周面をシェービング加工することを特徴とする整流子の製造方法。In the manufacturing method of the commutator according to any one of claims 1 to 3 ,
A method of manufacturing a commutator, wherein the hole of the metal piece is formed by stamping and then the inner peripheral surface of the hole is shaved. 互いに所定ギャップを隔てつつ軸心周囲に放射状に配置されて全体として略円盤形状の整流面を有するとともにカーボン焼成物を含む複数の整流子片、
各前記整流子片の主として反整流面側の表面に接して前記整流面を露出させつつ前記各整流子片を支持し保護する樹脂製のボス部、及び、
各前記整流子片の反整流面側の表面に接合される整流子片接続部、及び、前記整流子片接続部の径外側の端部から前記ボス部の前記主部の外周面に沿って延在して巻線が接合される端子部をそれぞれ有する複数の金属片、
を備え、
前記整流子片は、前記整流面を有する基板部、及び、前記基板部の反整流面側の表面から突出する突部を有し、
各前記金属片の前記整流子片接続部は、前記突部が挿入される孔をそれぞれ有する整流子において、
前記孔への内周面に接触する前記突部の外周面は、前記カーボン焼成物の削り面で形成され、
前記突部の基端部の外周面に面して前記基端部と前記金属片との間に、前記整流子片の突部の削り粉を収容するポケットを有することを特徴とする整流子。A plurality of commutator pieces that are radially arranged around the axis center with a predetermined gap therebetween and have a generally disc-shaped rectifying surface as a whole and including a carbon fired product;
Resin bosses that support and protect each commutator piece while exposing the commutation surface in contact with the surface of the commutator piece mainly on the side opposite to the commutation surface; and
A commutator piece connecting portion joined to a surface of each commutator piece on the side opposite to the commutating surface, and an outer peripheral surface of the main portion of the boss portion from an outer diameter end portion of the commutator piece connecting portion. A plurality of metal pieces each having a terminal portion extending and joined to the winding;
With
The commutator piece has a substrate portion having the rectifying surface, and a protrusion protruding from the surface of the substrate portion on the side opposite to the rectifying surface,
The commutator piece connecting portion of each metal piece is a commutator having holes into which the protrusions are inserted, respectively.
The outer peripheral surface of the protrusion contacting the inner peripheral surface to the hole is formed by a shaving surface of the carbon fired product ,
Between the metal piece and the base end portion facing the outer peripheral surface of the proximal end portion of the protrusion, and wherein Rukoto that having a pocket for accommodating a grinding dust of projection of the commutator segments Commutator. 請求項５記載の整流子において、
前記削り面を形成して軸方向に延在する前記孔の内周面の挿入側周縁角部は、面取り部又はプレス垂れ部を有し、
前記面取り量又はプレス垂れ量は、前記内周面と、径方向に延在する前記整流子片の前記反整流面に対向する前記金属片の実質的な平坦面との交差点から前記内周面方向及び径方向に０．２ｍｍ以下の領域に有ることを特徴とする整流子。The commutator according to claim 5, wherein
The insertion side peripheral corner portion of the inner peripheral surface of the hole extending in the axial direction by forming the shaving surface has a chamfered portion or a press sagging portion,
The chamfering amount or the press sag amount is determined by measuring the inner peripheral surface from the intersection of the inner peripheral surface and a substantially flat surface of the metal piece facing the anti-rectifying surface of the commutator piece extending in the radial direction. A commutator having a region of 0.2 mm or less in the radial direction and the radial direction. 請求項５記載の整流子において、
前記突部は、３０００μΩ・ｃｍ以下の固有抵抗を有することを特徴とする整流子。The commutator according to claim 5, wherein
The protrusion has a specific resistance of 3000 μΩ · cm or less. 請求項５記載の整流子において、
前記突部は、金属粉を含むことを特徴とする整流子。The commutator according to claim 5, wherein
The commutator, wherein the protrusion includes metal powder. 請求項６記載の整流子において、
前記金属片は、厚さ方向一方側から他方側にプレス打ち抜きで形成された孔を有するプレス成形品からなり、
前記整流子片の突部は、前記金属片の一方側が前記突部の基端部に対面していることを特徴とする整流子。The commutator according to claim 6, wherein
The metal piece is a press-formed product having a hole formed by press punching from one side to the other in the thickness direction,
The protrusion of the commutator piece is configured such that one side of the metal piece faces a base end portion of the protrusion. 請求項５記載の整流子において、
前記突部の頂面と外周面とが交わる周縁角部は、なだらかに面取りされていることを特徴とする整流子。The commutator according to claim 5, wherein
The commutator is characterized in that a peripheral corner where the top surface and the outer peripheral surface of the protrusion intersect is gently chamfered. 請求項５記載の整流子において、
前記突部の前記外周面は、先細テーパ面からなることを特徴とする整流子。The commutator according to claim 5, wherein
The commutator, wherein the outer peripheral surface of the protrusion is a tapered tapered surface. 互いに所定ギャップを隔てつつ軸心周囲に放射状に配置されて全体として略円盤形状の整流面を有するとともにカーボン焼成物を含む複数の整流子片、
各前記整流子片の主として反整流面側の表面に接して前記整流面を露出させつつ前記各整流子片を支持し保護する樹脂製のボス部、及び、
各前記整流子片の反整流面側の表面に接合される整流子片接続部、及び、前記整流子片接続部の径外側の端部から前記ボス部の前記主部の外周面に沿って延在して巻線が接合される端子部をそれぞれ有する複数の金属片、
を備え、
前記整流子片は、前記整流面を有する基板部、及び、前記基板部の反整流面側の表面から突出する突部を有し、
各前記金属片の前記整流子片接続部は、前記突部が挿入される孔をそれぞれ有する整流子において、
前記金属片の前記孔は、周方向所定ピッチで形成された複数の小突起と、周方向に隣接する２つの前記小突起の間に形成される凹部とを有し、
前記凹部と前記整流子片の外周面との間に所定の径方向隙間をもち、前記整流子片の突部の削り粉を収容するポケットを有することを特徴とする整流子。A plurality of commutator pieces that are radially arranged around the axis center with a predetermined gap therebetween and have a generally disc-shaped rectifying surface as a whole and including a carbon fired product;
Resin bosses that support and protect each commutator piece while exposing the commutation surface in contact with the surface of the commutator piece mainly on the side opposite to the commutation surface; and
A commutator piece connecting portion joined to a surface of each commutator piece on the side opposite to the commutating surface, and an outer peripheral surface of the main portion of the boss portion from an outer diameter end portion of the commutator piece connecting portion. A plurality of metal pieces each having a terminal portion extending and joined to the winding;
With
The commutator piece has a substrate portion having the rectifying surface, and a protrusion protruding from the surface of the substrate portion on the side opposite to the rectifying surface,
The commutator piece connecting portion of each metal piece is a commutator having holes into which the protrusions are inserted, respectively.
Wherein the metal strip holes, possess a plurality of small projections formed in the circumferential direction by a predetermined pitch, and a recess formed between two of said small protrusions adjacent in the circumferential direction,
Commutator, characterized in that has a predetermined radial clearance between an outer peripheral surface of the commutator segments and the recesses, which have a pocket for accommodating a grinding dust of projection of the commutator segments. 請求項５乃至１２のいずれか記載の整流子を有することを特徴とする燃料ポンプ。Fuel pump and having a commutator according to any one of claims 5 to 12.
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