JP6082587B2 - Commutator, commutator manufacturing method, and rotating electric machine equipped with the commutator - Google Patents

Description

  The present invention relates to a commutator, a commutator manufacturing method, and a rotating electrical machine including the commutator, and more particularly, a commutator and a commutator manufacturing method capable of ensuring desired energization with a simple configuration, and the commutator. The present invention relates to a rotating electrical machine having a child.

In general, in a rotating electrical machine using a commutator, a rotating shaft serving as a rotation center of the rotating electrical machine is fixed to the commutator, and the armature is also fixed to the rotating shaft.
Then, the current flowing through the brush disposed so as to be in sliding contact with the commutator is rectified by the commutator, and the current flows through the winding wound around the armature, thereby generating a magnetic field.
The armature is configured to rotate by the attractive force / repulsive force of the permanent magnet acting on the magnetic field generated in the winding.

In a commutator provided in such a rotating electrical machine, a rotating electrical machine (DC motor) using an aluminum winding is considered for cost reduction or weight reduction.
Thus, when it is set as the structure which uses an aluminum coil | winding, the technique which improves the joining property of the copper commutator which is a different material, and an aluminum coil | winding is needed (for example, refer patent document 1).

Patent Document 1 discloses a configuration of a starter motor.
The armature coil of the starter motor described in Patent Document 1 is made of an aluminum wire.
And the segment which comprises a commutator (commutator) is formed with two members, the 1st annular body and the 2nd annular body.
That is, a first annular body made of aluminum is disposed on the inner peripheral portion of the segment, and a second annular body made of copper is disposed on the outer surface of the first annular body. Is formed.
And this segment is resin-molded with the ring which penetrates a shaft, and a commutator (commutator) is comprised.
Then, by joining the aluminum winding to the first annular body (made of aluminum) arranged on the inner side, and bringing the connected first annular body into contact with the second annular body made of copper , Which enhances the bondability between the two.

Full text and drawings of Japanese Utility Model Application No. 62-197809 (Japanese Utility Model Application Publication No. 01-101159)

  However, according to the technique described in Patent Document 1, the first annular body made of aluminum and the second annular body made of copper are energized by contact even though the metals are different. However, there is a possibility that the two are separated when the undercut of the segment is formed, and there is a possibility that desired energization cannot be performed.

  An object of the present invention is to solve the above-mentioned problems, and in using an aluminum winding to reduce cost and weight, a commutator and a commutator that can ensure sufficient energization with a simple configuration are provided. It is in providing a manufacturing method and a rotary electric machine provided with this commutator.

According to the commutator according to the present invention, the above-described problem is a commutator including a plurality of commutator segments arranged in the circumferential direction, and the commutator segments are aligned in the circumferential direction on the outer surface of the commutator. and copper segment main body forming a side profile of the commutator and the aluminum claws aluminum windings are connected to constitute the armature is configured with a said segment body A connecting portion for locking the claw portion on the inner surface, the claw portion extending outside the commutator and arranged in a circumferential direction to connect the windings. A line connecting portion, and a connected portion that extends in an axial direction from the winding connecting portion and is connected to the connecting portion formed in the segment body, and the connecting portion is A bottom piece extending radially inward from the inner wall of the commutator segment; A sandwiching piece standing in an axial direction from the bottom piece toward the side where the winding connection part is formed, and the inner wall of the commutator segment and the sandwiching piece, A portion where the portion is formed is sandwiched, and the plurality of commutator segments aligned in the circumferential direction are integrated by a resin portion formed inside, and the resin portion is connected to the connecting portion and the It is formed in a state that encompasses and the connected portion therein is solved by Tei Rukoto.

  In addition, the above-described problem is provided with a copper segment body that is aligned with the outer surface in the circumferential direction to form a side profile, and an aluminum claw portion to which an aluminum winding that constitutes the armature is connected. A commutator manufacturing method comprising a plurality of commutator segments aligned in the circumferential direction, wherein the commutator segments extend outside the commutator and are aligned in the circumferential direction. Among the claw portions configured to have a winding connection portion to be connected and a connected portion that extends in the axial direction from the winding connection portion and is connected to the connecting portion formed in the segment body. The connected portion is arranged on a connecting portion formed on an inner wall of a ring-shaped segment prototype formed in an annular shape so as to be aligned in the circumferential direction with the winding connecting portion extending outward. And joining the connecting part and the connected part. In the second step, the inside of the segment prototype is filled with resin, molded in a state including the junction between the connecting portion and the connected portion, and the adjacent nail portions are divided at the outer surface. In this way, the third step of forming the plurality of commutator segments by undercutting in the axial direction and the fourth step of joining the windings to the winding connection part are solved.

By being comprised in this way, the junction part of an aluminum nail | claw part and a copper segment main body will be located in a resin part.
That is, when resin molding is performed, molding is performed at the same time, and the bonded state can be reliably maintained.
Therefore, when performing so-called undercutting, it is possible to effectively prevent the claw portion and the segment body from being separated from each other, so that insufficient energization can be eliminated and desired energization can be ensured.
For this reason, the aluminum winding can be used effectively, which contributes to cost reduction and weight reduction.

At this time, it may be welded to the consolidated part and the connecting part.
Alternatively, the connecting portion includes a bottom piece extending radially inward from the inner wall of the commutator segment, and a sandwiching piece standing in the axial direction from the bottom piece toward the side where the winding connection portion is formed. It is good also as a structure by which the site | part in which the said to-be-connected part was formed is clamped in the inner wall of the said commutator segment, and the said clamping piece.
Furthermore, in the form in which the coupled portion is clamped, the clamping piece and the portion where the coupled portion is formed may be fixed by caulking.

As described above, it is preferable that the claw portion and the segment main body are reliably connected by welding.
Further, when the connected portion is sandwiched between the inner wall of the commutator segment and the sandwiching piece, the claw portion can be simply coupled by simply press-fitting the coupled portion between the commutator segment and the sandwiching piece. This is preferable because it is possible.
Further, when the connected portion is sandwiched between the inner wall of the commutator segment and the sandwiching piece, if the sandwiching piece and the portion where the coupled portion is formed are fixed by caulking, further bonding force This is preferable because of the increase.

The rotating electrical machine according to the present invention is mounted on a commutator including a commutator segment that is electrically connected to a winding made of aluminum and arranged in the circumferential direction , a yoke, and an inner wall surface of the yoke. a plurality of magnets, and the rotation shaft serving as a rotation center, while being mounted on the rotary shaft, an armature which the winding is wound, comprising at least a sliding contact with the brush body to said commutator, the rectifier The child segment is an aluminum claw to which a copper segment body that is circumferentially aligned with the outer surface of the commutator to form a side contour of the commutator and an aluminum winding that constitutes the armature are connected. The segment body includes a connecting portion that locks the claw portion on an inner surface, and the claw portion extends outside the commutator and extends in the circumferential direction. The windings arranged in alignment A winding connection portion to be connected and a connected portion that extends in the axial direction from the winding connection portion and is connected to the connection portion formed in the segment body, and is arranged in the circumferential direction The plurality of commutator segments are integrated by a resin portion formed on the inside, and the resin portion is formed so as to include the connecting portion and the connected portion inside. .

According to the present invention, when the undercut is made by positioning the joint portion between the aluminum claw portion and the copper segment main body within the resin portion, the claw portion and the segment main body are effectively prevented from separating. can do.
For this reason, lack of energization can be solved and desired energization can be secured with a simple configuration.
Therefore, conventional problems can be solved, and aluminum windings can be used to reduce cost and weight.

It is sectional drawing which shows schematic structure of the motor which concerns on one Embodiment of this invention. It is a perspective view of a commutator concerning one embodiment of the present invention. It is the sectional view on the AA line of FIG. It is process drawing which shows the manufacturing process of the commutator which concerns on one Embodiment of this invention. It is explanatory drawing which shows the manufacturing process of the commutator which concerns on one Embodiment of this invention. It is explanatory drawing which shows the junction structure of the segment main body and claw part which concern on one Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Note that the configuration described below does not limit the present invention and can be variously modified within the scope of the gist of the present invention.
The present embodiment relates to a rotating electrical machine that can ensure sufficient energization with a simple configuration when an aluminum winding is used as a winding in order to reduce cost and weight.

  1 to 6 show an embodiment of the present invention. FIG. 1 is a sectional view showing a schematic configuration of a motor, FIG. 2 is a perspective view of a commutator, and FIG. 3 is a line AA in FIG. FIG. 4 is a process diagram illustrating the commutator manufacturing process, FIG. 5 is an explanatory diagram illustrating the commutator manufacturing process, and FIG. 6 is an explanatory diagram illustrating a joint structure between the segment body and the claw portion.

With reference to FIG. 1, an example of the configuration of a motor M (rotary electric machine) according to the present embodiment will be briefly described.
The motor M according to the present embodiment adopts a DC motor configuration.
As shown in FIG. 1, the motor M according to the present embodiment generates a field as a shaft 1 serving as an output shaft, an armature 3 around which a winding 2 is wound, a commutator 4, and a field. The main component is a magnet 5 to be stored and a yoke 6 in which these are housed and to which the magnet 5 is fixed.

The shaft 1 is rotatably supported by a yoke 6 via a bearing 7.
In the present embodiment, a unidirectional rotating motor is exemplified as the motor M, and thus the shaft 1 is configured to rotate in one direction.
An armature 3 is fixed to the shaft 1, and a magnet 5 is disposed around the armature so as to surround the outer periphery of the armature 3.
The magnet 5 is a permanent magnet and is fixed to the inner wall surface of the yoke 6.
A commutator 4 is also fixed to the shaft 1.

The armature 3 according to the present embodiment includes an armature core 13 and a winding 2 wound around the armature core 13.
The winding 2 is made of aluminum.
For this reason, it is possible to reduce costs and to reduce the weight at the same time as compared with the case of using a copper wire.
The armature core 13 according to the present embodiment is a laminated core formed by laminating a plurality of core sheets 113 in the axial direction.
These core sheets 113 are made of, for example, a thin sheet-like plate material such as a silicon steel plate, and are processed into a predetermined shape by performing a press punching process.

The commutator 4 according to this embodiment is a cylindrical member that rotates integrally with the shaft 1 in one direction, and includes a plurality of commutator segments 40 that are arranged at regular intervals along the rotation direction. It is configured.
The commutator 4 is configured such that the commutator segment 40 that contacts the brush body of the brush device is switched with rotation. With this configuration, the direction of the current flowing through the winding 2 is switched.
The adjacent commutator segments 40 and 40 are adjacent to each other with an undercut groove 41c that is a gap (a groove extending in the axial direction) formed by undercut therebetween.
The configuration of the commutator 4 is a main component of the present invention, and will be described in detail later.

Note that the rotating electrical machine according to the present embodiment is equipped with a brush device.
This brush device is for passing a current through the coil 2 through the commutator 4, and a known brush device may be used.
As an example, this brush apparatus is equipped with a brush body mainly composed of carbon or the like. A spring that biases the brush body in the direction of the commutator 4 is stored in a storage box that is supported, and the brush body is biased in the direction of the commutator 4 by the spring. With this configuration, one end surface of the brush body comes into sliding contact with the commutator 4.
The brush body is connected to a pigtail fed from a lead wire for feeding, and can be fed from outside.

Next, the commutator 4 according to the present embodiment will be described with reference to FIGS. 2 and 3.
The commutator 4 is a cylindrical member in which a through hole 51 for allowing the shaft 1 to pass through is formed at the center.
The commutator 4 according to the present embodiment includes a commutator segment 40 and a resin portion 50 as main components, and is configured to have a cylindrical shape with a plurality of commutator segments 40 aligned in the circumferential direction. Yes.
In the present embodiment, an example in which 18 commutator segments 40 are arranged in the circumferential direction is shown.

The commutator segment 40 includes a segment main body 41 and a claw portion 42.
The segment body 41 is a flat plate member whose outer surface is gently curved (curved so as to form a cylinder when 18 are aligned), and is composed of copper in this embodiment. .
On the inner wall of the segment main body 41, a segment inner groove 41a for arranging a connected portion 42b constituting a claw portion 42 described later is formed so as to extend along the axial direction.
In the present embodiment, since 18 claw portions 41 are arranged, 18 segment inner grooves 41a are arranged at equal intervals in the circumferential direction, and 18 claw portions 42 are arranged in the 18 segment inner grooves 41a. Are arranged respectively.

The segment inner groove 41a has a groove depth (distance in the radial direction of the commutator 4: distance in the inner and outer directions) and a groove width (commutator 4) so as to match the shape of the connected portion 42b constituting the claw portion 42. (Distance in the circumferential direction) is set, and the connected portion 42b constituting the claw portion 42 is configured to be accommodated.
In addition, a connecting portion 41b to which a connected portion 42b of a claw portion 42 to be described later is connected is formed inside the in-segment groove portion 41a. In addition, although mentioned later, in this embodiment, since the segment main body 41 and the connection part 42 are joined by spot welding, this connection part 41b will point a welding point.

Further, the claw portion 42 according to the present embodiment is made of aluminum, and is formed so as to have a winding connection portion 42a formed in a hook shape and an inner corner forming approximately 90 ° (formed in a step shape). And a connected portion 42b.
That is, as shown in FIGS. 1 and 2, the winding connection portion 42 a constituting the claw portion 42 extends to the outside of the segment main body 41 in a state where it is disposed in the segment main body 41 aligned in a cylindrical shape. It bends like a hook.

And the to-be-connected part 42b is horizontal toward the inner side direction of the commutator 4 from the inner side edge part (end part on the opposite side to the hook edge part extended outside the segment main body 41) of the coil | winding connection part 42a. After extending, it bends substantially perpendicularly and extends in the axial direction in the direction opposite to the side where the winding connection portion 41a is disposed.
Since it is comprised in this way, the to-be-connected part 42b will have an inner corner which comprises about 90 degrees.

The depth of the inner corner (distance in the commutator 4 radial direction: distance in the inner and outer directions) is the depth of the segment inner groove 41a formed in the segment body 41 (in the direction from the outer side to the inner side of the commutator 4). Distance).
For this reason, the connected portion 42b constituting the claw portion 42 is inserted into the segment inner groove 41a formed in the segment main body 41, and one end portion of the segment inner groove 41a formed in the segment main body 41 (winding connection portion). 42a is arranged in the inner corner of the coupled portion 42b (the inner corner of the coupled portion 42b covers one end of the segment inner groove 41a).
Thus, the claw part 42 can be locked with respect to the segment main body 41 (segment inner groove 41a), and positioning becomes easy.

As described above, the commutator 4 according to the present embodiment has a cylindrical shape in which a plurality (18) of commutator segments 40 (the state in which the claw portions 42 are joined to the segment body 41) are aligned in the circumferential direction. In the state, it is molded with resin (the resin portion is “resin portion 50”).
At this time, the winding connection portions 42 a constituting the claw portions 42 are aligned in the circumferential direction in a state of extending to the outside of the commutator 4.
Adjacent commutator segments 40 are adjacent to each other with an undercut groove 41c as a predetermined gap interposed therebetween.
And the through-hole 51 penetrated to an axial direction is formed in the center part, and the shaft 1 can penetrate.

Next, a method for manufacturing the commutator 4 according to this embodiment will be described with reference to FIGS.
The segment main body 41 constituting the commutator segment 40 is formed by being separated from the segment prototype 410 formed in a thin cylindrical shape (ring shape) by an undercut before the manufacturing.
In other words, in the present embodiment, one segment prototype 410 is undercut along the axial direction and divided into 18 equal parts to form individual segment bodies 41.

First, as shown in step 1 of FIG. 4 and FIG. 5A, a “claw portion disposing step” in which the claw portion 42 is disposed on the segment pattern 410 is performed.
In the claw portion disposing step, the connected portions 42b constituting the claw portion 42 are formed in the segment inner grooves 41a formed in the segment prototype 410 (18 in this embodiment, aligned at equal intervals in the circumferential direction). To be inserted).
In the present embodiment, the 18 claw portions 42 are arranged at equal intervals along the circumferential direction of the segment body 41.
Specifically, the winding connection part 42a which comprises the nail | claw part 42 will extend to the outer side of the segment original pattern 410, and will align with the circumferential direction.
Note that the arrows in FIG. 5 (a) are shown only in one place because the figure becomes complicated.

Next, as shown in Step 2 of FIG. 4 and FIGS. 5B and 6A, the connected portion 42b constituting the claw portion 42 and the connecting portion 41b formed in the segment prototype 410 are joined. Do.
In addition, since the figure becomes complicated, the welding point G1 in FIG.
In the present embodiment, as shown in FIG. 6 (a), both are joined at a welding point G1 by "spot welding" in which both are crimped and an electric current is passed and the metal is melted and joined by the resistance heat. To do.

In addition, regarding this joining method, it is not restricted to this, What kind of method may be employ | adopted as long as both can be joined, without deviating from the meaning of this invention.
For example, as shown in FIG. 6B, a connecting portion 41b is formed on the bottom surface (inner wall surface) of the segment inner groove 41a as a hook-like structure so as to cover the free end side of the connected portion 42b. May be.

That is, the connecting portion 41 b having this configuration is configured by the bottom piece 141 and the sandwiching piece 142.
The bottom piece 141 is a substantially rectangular portion that extends horizontally from the bottom surface (inner wall surface) of the segment inner groove 41a toward the inner side of the commutator 4 (the direction toward the radial center). When the portion 42 is disposed, it is slightly lower in the drawing than the position where the free end of the coupled portion 42b is disposed (on the side opposite to the side where the winding connection portion 42a is formed and the axial direction). .

The sandwiching piece 142 is a substantially rectangular portion that stands substantially vertically above the inner end of the bottom piece 141 (in the drawing and on the same side in the axial direction as the winding connection portion 42a).
The distance between the bottom surface (inner wall surface) of the segment inner groove 41a and the holding piece 142 (distance in the direction from the outer side to the inner side of the commutator 4: radial distance) is substantially equal to the thickness of the connected portion 42b. It is configured to be the same or slightly smaller than the wall thickness.

Therefore, the connected portion 42b is inserted into the segment inner groove 41a, and the free end portion side is press-fitted between the bottom surface (inner wall surface) of the segment inner groove 41a and the holding piece 142, so that the claw portion 42 is segmented. It can be attached to the prototype 410.
With this configuration, there is no need for welding or the like.
In addition, as shown in FIG. 6C, when the portion is caulked at the caulking point G2, the claw portion 42 can be more securely attached to the segment pattern 410.

Next, as shown in Step 3 of FIG. 4 and FIG. 5C, resin molding is performed in a state where the claw portion 42 is disposed on the segment prototype 410, and the molded product is undercut, and adjacent The nail | claw parts 42 and 42 to perform are parted.
As a result, the commutator segments 40 are aligned with the undercut groove 41c interposed therebetween.
In addition, according to this embodiment, the junction part of the segment main body 41 and the nail | claw part 42 is a structure arrange | positioned only inside the resin part 50, and the said junction part will be resin-molded completely.
Even if the undercut is performed in such a state, the segment main body 41 and the claw portion 42 are not separated, and good energization can be realized.

Then, as shown in Step 3 of FIG. 4, at the fusing point F (see FIG. 6A), the end of the winding 2 is locked to the winding connecting portion 42 a constituting the claw portion 42. Fusing caulking is performed, and the winding 2 and the claw portion 42 are connected.
As described above, the commutator 4 according to the present embodiment is formed.

In the present embodiment, aluminum is used as the material of the claw portion 42, but the material is not limited to this.
Table 1 below shows a table in which “standard electrode potential of metal” is described.

  In Table 1, when a metal having a standard electrode potential between copper and aluminum (described as “range R”) is used as a material constituting the claw portion 42, the electrode potential difference from copper constituting the segment body 41 is small. This is advantageous in corrosion countermeasures.

1. Shaft (rotary axis),
2. Winding,
3. Armature,
13 .... Armature core, 113 ... Core sheet,
4 ・ ・ Commutator,
40 .. Commutator segment,
41 ·· Segment body, 41a ·· Segment in groove, 41b ·· Connecting portion,
41c..Undercut groove,
42 .. Claw part, 42 a .. Winding connection part, 42 b.
141 .. bottom piece, 142 .. sandwiching piece,
410 · · segment prototype,
50..Resin part, 51..Through hole,
5. Magnets
6. York
7. Bearings
F. fusing point,
G1 ... welding point, G2 ... caulking point,
M ・ ・ Motor

Claims (4)

A commutator including a plurality of commutator segments arranged in the circumferential direction,
The commutator segment is
A copper segment body that is aligned with the outer surface of the commutator in the circumferential direction to form a side profile of the commutator; and an aluminum claw portion to which an aluminum winding constituting the armature is connected. It is configured to have,
The segment body includes a connecting portion that locks the claw portion on an inner surface,
The nail portion is
A winding connection portion that extends outside the commutator and is aligned in the circumferential direction to connect the windings;
A connected portion that extends in an axial direction from the winding connecting portion and is connected to the connecting portion formed in the segment body ,
The connecting portion is
A bottom piece extending radially inward from the inner wall of the commutator segment;
From the bottom piece, a sandwiching piece standing in the axial direction toward the side where the winding connection portion is formed,
In the inner wall of the commutator segment and the clamping piece, the portion where the connected portion is formed is clamped,
The plurality of commutator segments aligned in the circumferential direction are integrated by a resin portion formed inside,
The resin portion commutator, characterized in Tei Rukoto formed in a state that encompasses said the connected portion between the coupling portion therein. The commutator according to claim 1 , wherein the sandwiching piece and the portion where the connected portion is formed are fixed by caulking. The aluminum winding and electrically connected to a commutator having a commutator segments having a plurality circumferentially arranged,
York,
A plurality of magnets mounted on the inner wall surface of the yoke;
A rotation axis as a center of rotation;
An armature mounted on the rotating shaft and wound with the winding;
A brush body in sliding contact with the commutator ,
The commutator segment is
A copper segment body that forms a side profile of the commutator in a circumferential direction aligned with the outer surface of the commutator, and an aluminum claw portion to which the aluminum windings that constitute the armature are connected, Comprising
The segment body includes a connecting portion that locks the claw portion on an inner surface,
The nail portion is
A winding connection portion that extends outside the commutator and is aligned in the circumferential direction to connect the windings;
A connected portion that extends in an axial direction from the winding connecting portion and is connected to the connecting portion formed in the segment body,
The plurality of commutator segments aligned in the circumferential direction are integrated by a resin portion formed inside,
The rotary electric machine is characterized in that the resin portion is formed so as to include the connecting portion and the connected portion . A plurality of commutator segments including a copper segment body that is aligned with the outer surface in the circumferential direction to form a side profile, and an aluminum claw portion to which an aluminum winding constituting the armature is connected Is a method of manufacturing a commutator arranged in the circumferential direction,
A coil connecting portion that extends outside the commutator and is aligned in the circumferential direction, connects the windings, and extends in the axial direction from the winding connecting portion, and is formed on the segment body. Of the claw portions configured to have a connected portion connected to the connected portion, the connected portion is formed on the inner wall of a ring-shaped segment prototype formed in an annular shape. A first step of arranging the winding connection portion in a circumferential direction in a state where the winding connection portion extends in an outer direction;
A second step of joining the connecting portion and the connected portion;
Fill the inside of the segment prototype with resin, mold in a state including the joint between the connecting part and the connected part, and axially so as to divide between the adjacent claw parts at the outer surface A third step of undercutting to form a plurality of commutator segments;
And a fourth step of joining the windings to the winding connection part.

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