JP6813886B2 - DC motor with brush and its manufacturing method - Google Patents

Description

The present invention relates to a brushed DC motor and a method for manufacturing the same.

Brushed DC motors are widely used in various fields as drive sources for equipment that composes various control systems, and their applications are expanding more and more. For example, a brushed DC motor is used as a motor for opening and closing valves of an intake system and an exhaust system of an automobile engine, a power seat, and a drive source for opening and closing windows, trunks, or back doors.
A DC motor with a brush uses a brush to perform rectification with a commutator, and electromagnetic noise is generated by sparks generated when the commutator comes into contact with the brush during rectification. In addition, noise is also generated due to the influence of the inductance of the armature coil during rectification. Depending on the environment in which the DC motor is installed, a noise prevention circuit is attached to the DC motor as a countermeasure against noise in these wide frequency bands.

For in-vehicle direct current motors, in order to eliminate adverse effects on other electrical components such as in-vehicle engine controllers, the regulation of the allowable value of noise generated by brushes is defined as an EMC (electric magnetic compatibility) standard. It is regulated internationally.

As a DC motor provided with a noise prevention circuit, in Patent Document 1, a choke coil and a capacitor are installed in a brush holder, and a relatively high frequency noise generated in a power supply circuit is absorbed by the choke coil. , Those with relatively low frequencies are disclosed to be absorbed by a capacitor.
Further, in Patent Document 2, as a noise prevention circuit compliant with the EMC standard, a choke coil is provided on the front side of the brush plate facing the armature, and a capacitor (common mode compatible) is provided on the back side of the choke coil. Those connected via an insert terminal provided on the side are disclosed. The choke coil is fixed along the surface side of the end cap body.
Further, Patent Document 3 discloses a DC motor in which a printed circuit board on which a noise prevention circuit is mounted is provided on an end cap.

Japanese Unexamined Patent Publication No. 2004-56894 Japanese Unexamined Patent Publication No. 2015-70658 Japanese Unexamined Patent Publication No. 2008-178249

As a DC motor for automobiles, a two-pole brushed permanent magnet type DC motor (hereinafter referred to as a brushed DC motor) that has the same torque characteristics in both forward and reverse directions takes advantage of its small size and low price. , Has been widely adopted.
Control systems are becoming smaller and lighter due to the needs for fuel efficiency and cost reduction in automobiles. In addition, due to the tightening of environmental regulations, the control system is required to have higher accuracy and higher reliability. In addition, there is a demand for improved safety / comfort. For example, as new electronic control devices are installed in trunk rooms where noise countermeasures were initially unnecessary, motors with noise suppression functions may be required. Alternatively, a motor with a higher noise suppression function may be required in order to provide a more comfortable environment when the user uses an electronic device such as an audio device in the vehicle interior.

On the other hand, depending on the installation environment of the DC motor, there are places where it is usually assumed that a noise prevention circuit is unnecessary, such as a motor for opening and closing a trunk. A DC motor without a noise prevention circuit is adopted in such a place from the viewpoint of giving priority to low fuel consumption / cost reduction.
DC motor manufacturers need to flexibly respond to these various demands.

Conventional brushed DC motors are motors that do not comply with the EMC standard that prioritize low fuel consumption / cost reduction, and noise prevention circuits that comply with the EMC standard in consideration of high accuracy and high reliability, depending on the intended use. The motor attached with the above is designed and manufactured separately.

The inventions described in Patent Documents 1 to 3 do not fully consider the needs for low fuel consumption / cost reduction and the needs for high accuracy / high reliability and safety / comfort improvement.
For example, the invention described in Patent Document 1 is not suitable for satisfying the demand for low fuel consumption / cost reduction because the choke coil is installed in the direction parallel to the axis of the motor and the shape of the entire brush holder becomes large. ..
Further, in the invention described in Patent Document 2, a noise prevention circuit compliant with the EMC standard is provided across both side surfaces of the brush plate, but the connection circuit between the components of the noise prevention circuit and the terminal becomes complicated. , Not suitable for meeting the demands of low fuel consumption / cost reduction.
Further, the invention described in Patent Document 3 has a configuration in which an end cap and a printed circuit board on which a noise prevention circuit is mounted are connected, and is not suitable for satisfying the demand for low fuel consumption / cost reduction.
Further, none of the patent documents discloses sufficient measures for flexibly responding to various demands for DC motors.

One of the problems to be solved by the present invention is to provide a brushed DC motor and a manufacturing method thereof that can flexibly meet the needs for high accuracy and high reliability while meeting the needs for low fuel consumption / cost reduction. To do.
Another problem to be solved by the present invention is to provide a brushed DC motor and a method for manufacturing the same, which can flexibly respond to unexpected specification changes such as demands for improving safety / comfort.

According to one aspect of the present invention, a magnet arranged on the inner peripheral side of the motor case, a rotor having an armature winding and a commutator, a pair of brushes in sliding contact with the commutator, and the motor case. In a DC motor provided with an end cap fixed to one end and holding the brush, the end cap is provided at a position facing the end cap main body and the surface side of the end cap main body so as to hold the pair of brushes. A pair of brush holder holding portions for holding, slits for terminals 1 to 4 and terminals provided near the outer edge of the end cap body and penetrating from the front surface side to the back surface side of the end cap body, and the end. A first choke coil holding groove and a second choke coil holding groove are provided between the pair of brushes on the surface side of the cap body, and the first and second terminal / terminal slits are the first choke. The positions for sandwiching the coil holding groove, the third and fourth terminal terminal slits are located for sandwiching the second choke coil holding groove, and the planar shape of the first to fourth terminal terminal slits is The end cap body is the same, and the end cap body is on the surface side of the end cap body and radially outside the choke coil holding groove, respectively, at least one commutator holding portion and at least one resistance holding portion. It has .
As a result, the end cap can be used for both EMC standard compliant and non-EMC compliant DC motors, meeting the needs for cost reduction and flexibly responding to the needs for high accuracy and high reliability. It is possible to provide a brushed DC motor.

According to another aspect of the present invention, the slits for terminals 1 to 4 each have a slit portion and a claw receiving portion extending radially from both sides of the slit. As a result, the end cap can be used for both EMC standard compliant and non-EMC compliant DC motors, and it is possible to meet the needs for cost reduction.

According to another aspect of the present invention, the power supply terminal and the relay terminal corresponding to the slits for each terminal / terminal are provided, and the power supply terminal has a connection terminal, a step portion, a fixed claw portion, and a terminal terminal. The relay terminal has a connection terminal, a step portion, a fixed claw portion, and an insertion portion, and the terminal terminal of the power supply terminal and the insertion portion of the relay terminal are slits for the terminal / terminal. The fixed claw portion of the power supply terminal and the fixed claw portion of the relay terminal have the same cross-sectional shape that can be inserted into the slit portion, and the fixed claw portion of the relay terminal has the same cross-sectional shape that can be inserted into the claw receiving portion. ..
As a result, it is possible to provide a brushed DC motor that can meet the needs for high accuracy and high reliability while meeting the needs for cost reduction by properly using the power supply terminal and the relay terminal.

According to another aspect of the present invention, the end cap is composed of the end cap main body and a shield cap, and the shield cap is a bearing corresponding to a boss portion provided in a central portion of the end cap main body. It has a holding part. This makes it possible to provide a brushed DC motor having a function of suppressing radiation noise while meeting the needs for cost reduction.

According to another aspect of the present invention, in the brushed DC motor, the first brush and the second brush constituting the pair of brushes, and the first relay terminal and the first relay terminal corresponding to the first brush. The power supply terminal, the second relay terminal corresponding to the second brush, and the second power supply terminal are provided, and the first brush is connected to the connection terminal of the first relay terminal. The second brush is connected to the connection terminal of the second relay terminal, the first relay terminal is fixed to the slit for the first terminal terminal, and the slit for the third terminal terminal is connected to the slit. The second relay terminal is fixed, the connection terminal of the first power supply terminal is connected to the slit for the second terminal / terminal, and the second power supply terminal is connected to the slit for the fourth terminal / terminal. Connection terminal is connected.
This makes it possible to provide a DC motor that complies with the EMC standard while meeting the needs for cost reduction.

According to another aspect of the present invention, in a brushed DC motor, the first brush and the second brush constituting the pair of brushes are provided, and the first brush is for connecting a first power supply terminal. The second brush is connected to the terminal, the second brush is connected to the connection terminal of the second power supply terminal, the first power supply terminal is fixed to the first terminal terminal slit, and the third terminal is connected to the terminal. The second power supply terminal is fixed to the terminal slit.
This makes it possible to provide a DC motor that does not support EMC while meeting the needs for cost reduction.

According to another aspect of the present invention, a second condenser holding portion is provided on the back surface of the end cap main body, the second condenser is fixed to the second condenser holding portion, and the end cap main body communicates with each other. It has holes, and the second condenser and the pair of power terminal connection terminals are connected by wiring through the communication holes. As a result, it is possible to provide an EMC standard-compliant brushed DC motor that can meet the needs for further improvement of safety / comfort, which is compatible with the common mode and the normal mode, while meeting the needs for cost reduction.

According to another aspect of the present invention, there is a method for manufacturing a brushed DC motor, wherein the brushed DC motor has a magnet arranged on the inner peripheral side of the motor case, an armature winding, and a rectifier. The motor case, the magnet, and the rotor are provided with a rotor, first and second brushes that are in sliding contact with the rectifier, and an end cap that is fixed to one end of the motor case and holds the brushes. said first, second brush, and the end cap are both DC motor with noise suppression circuit, and a structure common to the DC motor of the noise countermeasure circuit free, as the end cap , Each has a pair of brush holder holding portions, first and second choke coil holding grooves, a groove for resistance connection, and a groove for connecting a condenser on the surface side of the end cap main body, and is located near the outer edge of the end cap main body. The process of preparing a standard end cap structure having slits for terminals 1 to 4 penetrating from the front surface side to the back surface side of the end cap body, and relay terminals from both sides of the end cap body. The step of sandwiching and fixing to the slits for terminals 1 and 3 and the step of sandwiching the power supply terminal from both sides of the end cap body and fixing it to the slits for terminals 2 and 4 terminal. The step of holding the first and second brushes in each of the brush holder holding portions, and connecting the first and second brushes to the power supply terminal via the relay terminal, and the above-mentioned between the relay terminal and the power supply terminal, and a step of connecting said noise countermeasure circuit, the first, second slit for the terminal pin is at a position sandwiching the first choke coil retaining grooves, wherein The third and fourth terminal / terminal slits are located at positions sandwiching the second choke coil holding groove.
This makes it possible to provide a brushed DC motor compliant with the EMC standard, which can meet the needs for high accuracy and high reliability while meeting the needs for cost reduction.

According to another aspect of the present invention, in the method for manufacturing a DC motor, the power supply terminal and the relay terminal have a stepped portion and a fixed claw portion, respectively, and the stepped portion is the surface of the end cap main body. By pressing the fixing claw portion from the back surface side of the end cap main body, the power supply terminal and the relay terminal are fixed to the end cap main body so as to sandwich both sides of the end cap main body.
As a result, it is possible to provide a brushed DC motor that can meet the needs for high accuracy and high reliability while meeting the needs for cost reduction by properly using the power supply terminal and the relay terminal.

According to another aspect of the present invention, in the manufacturing method of the direct current motor, the standard end cap structure, radially outward from the surface side and the choke coil retaining grooves of the end cap body, for the resistance connection of the groove, and has a groove for the Condesa connected, at the surface side of the end cap body, between the connection terminals of the relay terminal and the power supply terminals, respectively, to connect the choke coil, the Each end of the resistor and the condenser is connected to the connection terminal on the power supply terminal side of the choke coil, and the resistor and the other end of the condenser are connected to the motor case.
This makes it possible to provide a brushed DC motor compliant with the EMC standard, which can meet the needs for high accuracy and high reliability while meeting the needs for cost reduction.

According to another aspect of the present invention, in the method of manufacturing a DC motor, the standard end cap structure has a second condenser holding portion on the back surface side of the end cap main body, and the end cap main body is said to have a second condenser holding portion. surface and has a communication hole for communicating between said back surface, a second Condesa fixed to the second Condesa holding portion, the said power supply terminal and the relay terminals of the surface side of the end cap body The second condenser on the back surface side is connected by a conductor through the communication hole.
As a result, it is possible to provide an EMC standard-compliant brushed DC motor that can meet the needs for further improvement of safety / comfort, which is compatible with the common mode and the normal mode, while meeting the needs for cost reduction.

According to the present invention, a brushed direct current that can meet the needs for low fuel consumption / cost reduction by realizing motor applications suitable for various applications based on a highly versatile basic standard motor. A method for manufacturing a motor and a DC motor can be provided.
Further, according to the present invention, based on a standard motor equipped with an end cap having a common configuration, it contributes to the progress of electronic control and further improvement of safety / comfort, and is flexible to unexpected specification changes. It is possible to provide a DC motor with a brush and a method for manufacturing the same.

It is a figure which shows an example of the standardized component group of the DC motor based on one Embodiment of this invention. It is a figure which shows the example of the variation of the DC motor for each use realized by combining the standardized component group shown in FIG. 1A. It is a vertical sectional view of the DC motor which shows an example to which this invention is applied. It is a front view of the end cap of the DC motor of FIG. 2 based on one embodiment of the present invention. It is a side view of the end cap shown in FIG. 3A. It is a rear view of the end cap shown in FIG. 3A. It is a perspective view of the power supply terminal and a relay terminal in one Embodiment of this invention. It is a perspective view which shows the part of the end cap of the EMC standard compliant DC motor which becomes the 1st Example to which one Embodiment of this invention is applied. It is a back view of the end cap part of the DC motor which becomes the 1st Example. It is a power circuit diagram of the DC motor which becomes the 1st Example. It is a perspective view which shows the part of the end cap of the DC motor which does not correspond to the EMC standard which becomes the 2nd Example to which one Embodiment of this invention is applied. It is a back view of the end cap part of the DC motor which becomes the 2nd Example. It is a vertical sectional view of the DC motor conforming to the EMC standard which becomes the 3rd Example to which one Embodiment of this invention is applied. It is a front view of the end cap of a DC motor in a third embodiment. It is a side view of the end cap shown in FIG. 11A. It is a rear view of the end cap shown in FIG. 11A. It is a perspective view of the shield cap in the 3rd Example. It is a rear view of the end cap part of the EMC standard compliant (common mode and normal mode) DC motor which becomes the 4th Example to which one Embodiment of this invention was applied. It is a power circuit diagram of the DC motor corresponding to the EMC standard of FIG.

Hereinafter, embodiments of the DC motor according to the present invention will be described with reference to the drawings.
[Standardization of DC motor]
FIG. 1A shows an example of a standardized component group of a DC motor based on an embodiment of the present invention.
The brushed DC motor 100 has a cup-shaped metal motor case 12 commonly used for all variations of motors and a two-pole magnet 14 arranged on the inner peripheral side of the motor case as its components. And an end cap (standard end cap structure) 16 for holding the brush terminal structure 17.

The magnet 14 has variations having different characteristics depending on the motor output, for example, two sets. That is, either the dry magnet 141 or the wet magnet 142 is adopted and pressed and fixed to the inner peripheral side of the motor case by the magnet holder 143 to form the stator. Further, if necessary, the flux ring 11 is fixed to the outer periphery of the motor case 12. The flux ring 11 is provided to suppress leakage of magnetic flux from the outer peripheral surface of the motor case and improve the efficiency of the motor 100.
The rotor 15 has an armature winding and a commutator. As a winding specification, there are two sets of variations, a rotor 151 without skew and a rotor 152 with skew when it is necessary to further reduce electrical vibration and noise.
Bearing 13 is for holding the shaft at both ends of the rotor 15 to the motor case 12, there are two sets of variations of ball bearings and sleeve bare-ring. Depending on the motor application, ball bearings 131 and 135, or sleeve bare-rings 132, 133, 134 or the like is employed. Motor case 12 and the standard end cap structure 16, respectively, also includes a locatable boss bare-ring of any variations. 121 is a color, it is installed at both ends of the sleeve bare-ring 132. As the ball bearing, either a single ball bearing or a double ball bearing can be selected.

Further, the standard end cap structure (sometimes simply referred to as an end cap) 16 has an insulating resin mold for its main body, and the materials thereof include, for example, polyamide 66 and polyamide 46 in consideration of heat resistance. is there. The standard end cap structure 16 may or may not be provided with EMC, and also has a shield cap having higher noise resistance, and there are, for example, four sets of variations as a whole. That is, the standard end cap structure 16 is an end cap (integrated type) 161 and an EMC standard compliant noise prevention circuit 19 (with or without), and an end cap (split type) 163 and an EMC standard compliant noise prevention circuit 19 (with). , None), and EMC standard compliant noise prevention circuit 19 (common mode and normal mode) 164.
The end cap (integrated type) 161 has a boss portion integrally formed on the back surface side of the end cap main body to hold the bearing. The end cap (split type) 163 has a structure in which a shield cap 18 having a boss portion for holding a bearing is fixed to the back surface side of the end cap main body. The metal shield cap 18 is fixed to the metal motor case 12 and has a function of suppressing radiation noise. However, in all variations, the end cap body is common in the configuration on the front side and the side surface facing the rotor.

The brush terminal structure 17 is basically a common configuration in that it includes a pair of brushes that are in sliding contact with the commutator and a pair of brush holders that are fixed to one end (open end) of the motor case and face each other. Is. However, the configuration of the member mounted on the standard end cap structure 16 differs depending on whether or not the EMC standard is supported.
[Standardized DC motor variations]

By combining the components of the standardized DC motor of FIG. 1A, variations of the DC motor as shown in FIG. 1B can be obtained. For example, DC motors 100A to 100F can be obtained depending on whether or not EMC standard is supported, whether or not a shield cap (radiation noise suppression) is used, whether or not EMC standard is supported (common mode and normal mode), and whether or not high temperature / high torque is supported.
[Standardized DC motor components]

Hereinafter, examples of standardized component groups of DC motors according to an embodiment of the present invention will be described in detail.
FIG. 2 is a vertical sectional view showing an example of a DC motor according to an embodiment of the present invention. The motor case 120 of the DC motor 100 is a metal case such as iron having a boss portion 124 on one end side 123 thereof and having an opening on the other end side. The end cap body 1610 made of an insulating resin is provided as the end cap structure 161 that closes the other end side of the motor case 120.
In the present invention, the surface (inner surface) 1613 of the end cap main body 1610 facing the rotor 15 is defined as the front surface of the end cap main body, and the opposite surface (outer surface) is defined as the back surface of the end cap main body.

The rotor 1520 has a shaft 1511 and a commutator 1512, and one end of the shaft 1511 is rotatably supported by a boss portion 124 via a bearing 131. The other end of the shaft 1511 is supported by a boss portion 1612 provided at the center of the end cap main body 1610 via a bearing 133. By electrically connecting the armature winding of the rotor 1520 to the commutator 1512, the commutator 1512 and the armature winding form the rotor 15 of the motor. The DC motor 100 further includes a pair of brushes 174 that are in sliding contact with the commutator 1512, and a brush holder that slidably holds the brushes 174. The brush holder is held by a brush holder holding portion formed on the surface of the end cap main body 1610. Near the radial outer edge of the end cap body 1610, terminals connected to the brush 174 via a pigtail 173 are provided, and these terminals extend to the back side of the end cap body 1610. It has 171-2. The brush holder 172 can be made of an insulating resin or a metal.
A driven member is connected to one end of the shaft 1511 either directly or via a gear.

Next, the configuration of the end cap 161 will be described in detail. As shown in FIGS. 3A to 3C, the end cap 161 includes an end cap main body 1610, a hole 1611, and a boss portion 1612 for holding a bearing. The end cap 161 is further formed at positions facing each other on the surface 1613 of the end cap body, and includes first and second brush holder holding portions 1614 for holding a pair of brushes facing each other.

On both sides of each brush holder holding portion 1614 of the end cap main body 1610, the first 1st to the back surface side facing the rotor 15 of the end cap main body penetrate at a position equidistant from the center of the end cap main body. Terminal 4 ・ Slits for terminals 1616-1 to 1616-4 are provided. The planar shapes of the slits for the terminals 1 to 4 (the shapes shown in the front view of FIG. 3A and the rear view of FIG. 3C) are the same.
That is, each terminal / terminal slit 1616 constitutes an intermediate portion thereof, for example, a rectangular slit portion 1633 and claw receiving portions 1631 and 1632 extending radially inward (or outward) at both ends of the slit portion. The slit portion 1633 in the intermediate portion has and extends linearly from the center of the end cap main body 1610 in a direction in contact with an arc at an equidistant distance. The planar shape of each terminal / terminal slit must correspond to the function of fixing both the power supply terminal 170A and the relay terminal 170B to the end cap body, but the specific shape is the cross-sectional shape of the power supply terminal. It should be decided in consideration of such factors.

Further, on the surface 1613 of the end cap body, there are two brush holding spring holding portions 1615, a choke coil holding groove 1617, a condesa holding portion 1618, a resistance holding portion 1619, and a spring holding 1620, which correspond to a pair of brushes. It is provided at the position of the set and the axis target. The condenser holding portion 1618 and the resistance holding portion 1619 are formed on the outside of the choke coil holding groove 1617.
That is, one choke coil holding groove is formed so as to extend along the surface 1613 of the end cap body on the surface side of the end cap body and between the slits 1616-1 and 1616-2 for the first and second terminals / terminals. 1617 is formed, and another choke coil holding groove 1617 is formed so as to extend along the surface 1613 of the end cap body between the slits 1616-3 and 1616-4 for terminals 3 and 4. Is formed. In other words, each terminal / terminal slit is provided on the surface 1613 of the end cap main body in the vicinity of each brush holder holding portion 1614 and on the side without the brush holding spring.

When the noise prevention circuit includes a plurality of capacitor elements having different capacities (corresponding to the common mode) and a plurality of resistance elements having different resistance values, the condenser holding unit 1618 and the resistance holding unit 1619 also have the plurality of elements. It is composed of a plurality of holding parts corresponding to. In the following, an example of a condenser holding unit 1618 corresponding to one element and a resistance holding unit 1619 corresponding to one element will be described.
Reference numeral 1625 is a communication hole for forming a spring retainer. Reference numeral 1626 is a notch for crimping the terminal or the terminal. Further, 1627 is a groove for resistance connection, 1628 is a groove for connection of a condenser, and 1629 is a detent. Reference numeral 1635 is the outer edge of the end cap body, which is fixed to the opening of the motor case 120.

Next, the structures of the power supply terminal and the relay terminal in one embodiment of the present invention will be described with reference to FIG. FIG. 4A shows the power supply terminal 170A, and FIG. 4B shows the relay terminal 170B. The connection terminal 176 (176-1,176-2) of the power supply terminal 170A and the connection terminal 179 (179-1,179-2) of the relay terminal 170B are both connected to a pigtail or the like. It has the same shape.
Both the power supply terminal 170A and the relay terminal 170B have a stepped portion 178 that functions as a stopper in the middle portion in the longitudinal direction thereof, and fixed claw portions 177 are provided on both sides of the stepped portion.

The terminal terminals 171-1 and 171-2 at the tip of the power supply terminal 170A are inserted into the slit portion 1633 of the terminal / terminal slit 1616 of the end cap main body 1610. Then, the fixed claw portion 177 is inserted through the claw receiving portions 1631 and 1632, and the fixed claw portion 177 is pressed from the back surface side of the end cap main body 1610 so as to sandwich the end cap main body with the stepped portion 178 of the terminal 170A. As a result, the power supply terminal 170A is fixed to the end cap main body 1610.
Similarly, for the relay terminal 170B, the central insertion portion 1715 is inserted into the slit portion 1633 of the terminal terminal slit 1616, and the fixed claw portion 177 at the tip of the step portion 178 inserted through the claw receiving portions 1631 and 1632 is ended. The relay terminal 170B is fixed to the end cap body 1610 by pressing it against the end cap body from the back surface side of the cap body 1610.
Both the power supply terminal 170A and the relay terminal 170B are fixed to the terminal / terminal slit 1616. Therefore, both the terminal terminal 171 of the power supply terminal 170A and the insertion portion 1715 of the relay terminal 170B have the same cross-sectional shape, for example, rectangular, which can be inserted into the slit portion 1633 of the terminal / terminal slit 1616. Further, the fixed claw portion 177 of the power supply terminal 170A and the fixed claw portion 177 of the relay terminal 170B can both be inserted into the claw receiving portions 1631 and 1632 of the terminal / terminal slit 1616, for example, having the same cross-sectional shape. have.
[Variation of noise suppression circuit]

As a noise suppression circuit for a DC motor of the present invention, there is a "standardized noise suppression circuit" corresponding to a standard end cap structure, which will be described later (see FIGS. 7 and 14). In an actual product, the necessary filter circuit components may be added or deleted based on the standardized noise suppression circuit according to the frequency band in which countermeasures are required.
For example, (1) a circuit in which only a choke coil is connected between terminals 171-1 and 171-2, (2) a circuit in which only a first capacitor is connected to the power supply terminal side of each choke coil, (3). ) A circuit in which only a resistor is connected to the power supply terminal side of each choke coil may be adopted. Alternatively, (4) instead of the pair of choke coils, a second capacitor was connected between terminals 171-1 and 171-2, and a capacitor and a resistor were connected to the power supply terminal side of the second capacitor. A circuit (see FIG. 7) may be employed. A circuit in which the choke coil is removed from the circuit of FIG. 14 may be adopted. The number and capacitance of capacitors, the number of resistors and the resistance value may be appropriately selected. In either case, by using the standard end cap structure in combination, it is possible to flexibly meet various demands while reducing costs.

Hereinafter, examples of a DC motor to which the standardized components of the DC motor according to the present invention are applied will be described in detail.

First, as a first embodiment to which one embodiment of the present invention is applied, a configuration example of a DC motor corresponding to the DC motor 100B of FIG. 1B will be described with reference to FIGS. 5 to 7.
FIG. 5 is a perspective view showing a portion of an end cap of the EMC standard compliant DC motor according to the first embodiment, FIG. 6 is a back view of the end cap, and FIG. 7 is a power supply circuit diagram.
The first brush 174 in the upper center of the figure and the second brush 174 in the lower center of the figure are pressed toward the commutator 1512 by the brush holding spring 175 held by the brush holding spring holding portion 1615, respectively. The first brush 174 is connected to the connection terminal 179-1 of the relay terminal 170B via the pigtail 173, and the insertion portion 1715 of the connection terminal is inserted into the slit 1616-1 for the first terminal terminal. .. In the relay terminal 170B, the stepped portion 178 of the relay terminal 170B is in contact with the bottom of the surface of the end cap body 1610, and the fixed claw portion 177 is pressed from the back surface side of the end cap body, in other words, the end cap body 1610. It is fixed to the end cap body so as to sandwich both sides.

An EMC standard compliant noise prevention circuit 19 is incorporated on the surface of the end cap body of the end cap 161. That is, one end of the choke coil 191 is connected to the connection terminal 179-1 of the relay terminal 170B. The other end of the choke coil 191 is connected to the connection terminal 176-1 of the first power supply terminal 170A fixed to the second terminal terminal slit 1616-2. A first condenser 193 (common mode) and a resistor 194 are connected to the connection terminal 176-1 via wirings 195a and 196a, respectively. The terminal terminal 171-1 of the first power supply terminal 170A is fixed to the end cap main body by pressing the fixing claw portion 177 from the back surface side of the end cap main body so as to sandwich both sides of the end cap main body 1610 (FIG. 6). The end of the wiring 195b that connects the ground side of the first condenser 193 to the motor case 120 is in the groove 1628 for connecting the condenser, and the end of the wiring 196b that connects the ground side of the resistor 194 to the motor case 120 is for resistance connection. Each is connected in the groove 1627.

For electrical connection between the connection terminal 176-1 of the terminal 170A, the other end of the choke coil 191 and the first condenser 193 (common mode) and the resistor 194, each wiring part is inside the connection terminal 176-1. After collecting and crimping, it is integrated by spot welding or the like.
Similarly, the second brush 174 in the lower center of FIG. 5 is connected to the connection terminal 179-2 of the relay terminal 170B via the pigtail 173, and the connection terminal 179-2 is connected to one end of the choke coil 192. Is connected. The other end of the choke coil 192 is connected to the connection terminal 176-2 of the second power supply terminal 170B fixed to the terminal / terminal slit 1616-4. The first condenser 193 (common mode) and resistor 194 are also connected to the connection terminal 176-2, and after gathering and crimping each wiring part inside the connection terminal 176-2, spot welding or the like is performed. , These are integrated and electrically connected.

The connection terminal P1 shown in the power supply circuit diagram of FIG. 7 corresponds to the connection terminal 179-1, and the connection terminal P2 corresponds to the connection terminal 179-2. Further, the terminals P3 and P4 connected to the positive terminal and the negative terminal of the battery correspond to the terminal terminals 171-1 and 171-2. Further, the connection terminals P5 to P18 correspond to the connection terminals 176-1 and 176-2, and the connection terminals P9 to P10 correspond to the ends of the wirings 195b and 196b connected to the motor case 120.

In this embodiment, the standard end cap structure 161 is a structure that can be used for a DC motor that does not support EMC, and the cost can be reduced by also using the standard end cap structure 161.

Further, the entire component of the noise prevention circuit 19 conforming to the EMC standard is incorporated on the front side of the end cap main body 1610. That is, the front side of the end cap main body 1610 of the standard end cap structure has a structure having a function as a substrate on which all the components of the noise prevention circuit can be mounted. Further, the connection terminal of the terminal and the connection terminal of the relay terminal are common. By adopting these configurations, it is possible to promote the sharing of parts and the standardization of work. This makes it possible to incorporate a noise prevention circuit while maintaining a compact and lightweight configuration, and meets the needs for low fuel consumption / cost reduction, high accuracy / high reliability, and safety / comfort improvement. Can be done.

As described above, according to the present embodiment, it is possible to provide a brushed DC motor that can meet various needs such as high accuracy and high reliability while meeting the needs for fuel efficiency and cost reduction.

Next, as a second embodiment to which one embodiment of the present invention is applied, a configuration example of a DC motor that does not comply with the EMC standard, which corresponds to the DC motor 100A of FIG. 1B, is shown with reference to FIGS. 8 to 9. explain. FIG. 8 is a perspective view showing a portion of the end cap of the DC motor, and FIG. 9 is a back view of the end cap portion.
The first brush 174 in the upper center of FIG. 8 is connected to the connection terminal 176-1 of the first power supply terminal 170A via the pigtail 173. The lower second brush 174 is also connected to the connection terminal 176-2 of the second power supply terminal 170B via the pigtail 173. The first power supply terminal 170A is fixed to the terminal / terminal slit 1616-1, and the second power supply terminal 170B is fixed to the terminal / terminal slit 1616-3. Both the terminal terminals of the power supply terminals 170A and 170B are fixed to the end cap main body by pressing and sandwiching the fixing claw portion 177 from the back side in a state where the step portion 178 is in contact with the front side of the end cap main body.
The terminal terminal 171-1 of the first power supply terminal 170A corresponds to the terminal P3 shown in the power supply circuit diagram of FIG. 7, and the terminal terminal 171-2 of the second power supply terminal 170B corresponds to the terminal P4.

When a filter circuit in which the choke coil is removed is adopted as the noise prevention circuit, the filter circuit may be connected between the power supply terminals 170A and 170B and the motor case (earth).

In this embodiment, not only the basic structure such as the motor case and the rotor, but also the standard end cap structure 161 and the terminal terminal, the relay terminal, etc. have a structure that can be shared with the DC motor compliant with the EMC standard, and these are also used. By doing so, the cost can be reduced. In particular, the front side of the end cap body 1610 of the standard end cap structure has a structure that functions as a board on which all the components of the noise prevention circuit can be mounted, thereby maintaining a compact and lightweight configuration. Even if the end cap body 1610 is used as it is for a DC motor that does not comply with the EMC standard, it does not cause a cost increase and can satisfy the needs for low fuel consumption / cost reduction.
As described above, according to the present embodiment, it is possible to provide a DC motor with a brush that can meet the needs for fuel efficiency reduction / cost reduction.

Next, as a third embodiment to which one embodiment of the present invention is applied, a brushed DC motor to which a shielding function against electromagnetic noise is added will be described. The brushed DC motor of this embodiment is provided with a metal shield cap 18 that removes radiated noise caused by contact between the commutator and the brush during rotation through a motor case 120 that functions as a ground. ..
FIG. 10 is a vertical cross-sectional view of the EMC non-compliant DC motor 100 according to the third embodiment. The standard end cap structure 163 of this embodiment is divided into an end cap main body 1610 and a shield cap 18.

11A to 11C show the configuration of the end cap 163 of the DC motor in the third embodiment. As shown in FIG. 11A, the configuration of the end cap main body 1610 is the same as the configuration of the end cap main body 1610 of the first and second embodiments except for the central boss portion and the bearing structure of the bearing. That is, as is clear from FIGS. 11B and 11C, the end cap main body 1610 of the third embodiment does not have the bearing holding portion 1612 of the first and second embodiments.
Instead, a bearing holding portion is formed between the boss portion 1612 of the end cap main body 1610 and the shield cap 18. That is, as shown in FIG. 12, the shield cap 18 has a bearing holding portion 1815 in its main body 1810. The bearing holding portion 1815 has a bearing holding claw 1814 around the central hole 1813. Reference numerals 1801 and 1802 are notches for passing terminal terminals 171-1 and 171-2, and 1812 and 1816 are positioning portions for fixing the shield cap main body 1810 to the motor case 120.

In this embodiment, the standard end cap structure 163 can be used for both an EMC non-compliant DC motor (corresponding to the DC motor 100C in FIG. 1B) and an EMC standard compliant DC motor (corresponding to the DC motor 100D in FIG. 1B). The cost can be reduced by using the standard end cap structure as well.
Further, the configuration of the main part of the end cap main body 1610 is the same as the configuration of the main part of the end cap main body 1610 of the first and second embodiments, and the cost can be reduced by standardizing the parts and standardizing the manufacturing process. ..

Furthermore, in addition to the EMC standard compliant function, a radiation noise suppression function has been added to meet the needs for low fuel consumption / cost reduction, while also meeting the needs for high accuracy, high reliability, and safety / comfort improvement. It is possible to provide a DC motor that can handle it.

Next, as a fourth embodiment to which one embodiment of the present invention is applied, another example of an EMC standard compliant DC motor (corresponding to the DC motor 100D in FIG. 1B) will be described.
FIG. 13 is a rear view of the end cap 164 of the EMC standard compliant DC motor 100. FIG. 14 is a power supply circuit diagram of the DC motor 100. In this embodiment, terminals P3 and P4 are connected to the positive and negative terminals of the battery. A second condenser 197 corresponding to the normal mode is connected between the pair of choke coils 191 and 192 via the connection terminals P11 and P1. These connection terminals P11 and P12 correspond to the connection terminals 176 (176-1,176-2) of the power supply terminals 170A and 170B in FIG. 7. A second condenser holding portion 199 is provided on the back surface of the standard end cap structure 1610, to which the second condenser 197 is fixed. The wiring 198 that connects the second condenser 197 and the connection terminals 176 of the power supply terminals 170A and 170B connects the front surface and the back surface of the standard end cap structure 1610 via two communication holes 1625. The outside of the end cap 164 is covered with a shield cap 18.

In this embodiment, the standard end cap structure 164 can be used for both an EMC non-compliant DC motor (corresponding to the DC motor 100C in FIG. 1B) and an EMC standard compliant DC motor (corresponding to the DC motor 100D in FIG. 1B). The cost can be reduced by using the standard end cap structure as well.

Next, as a fifth embodiment to which one embodiment of the present invention is applied, a DC motor compatible with high temperature and high torque will be described. In this embodiment, the shape of the standard end cap structure is the same as that of Examples 1 to 4. The brush holder 172 held in the standard end cap structure is made of metal, and by appropriately selecting the material of the standard end cap structure and the material of the magnet, a DC motor compatible with high temperature and high torque (DC in FIG. 1B). (Equivalent to motors 100E and 100F) can be realized.
Even in this case, the cost can be reduced by using the standard end cap structure for both the EMC standard compliant DC motor and the non-EMC compliant DC motor.

100 ... Brushed DC motor, 100A-100F ... Brushed DC motor 11 ... Flux ring, 12 ... Motor case, 121 ... Collar, 123 ... One end side of motor case, 124 ... Boss, 13 ... Bearing, 131 ... Ball bearing , 132 ... sleeve bare-ring, 133 ... sleeve bare-ring, 134 ... sleeve bare-ring, 135 ... ball bearing, 14 ... magnet 141 ... dry magnet, 142 ... wet magnet, 143 ... magnet holder, 15 ... rotor, 151 ... Rotor without skew, 1511 ... Shaft, 1512 ... Rectifier, 152 ... Rotor with skew, 1520 ... Rotor, 16 ... Standard end cap structure, 161 ... End cap (integrated type), 1610 ... End cap body, 1611 ... Hole, 1612 ... Boss part, 1613 ... End cap body surface, 1614 ... Brush holder holding part, 1615 ... Brush holding spring holding part, 1616 (1616-1, 1616-2, 1616-3, 1616-4) ... Terminal・ Terminal slit, 1617 ... Chalk coil holding groove, 1618 ... Condesor holding part, 1619 ... Resistance holding part, 1620 ... Spring retainer, 1625 ... Communication hole, 1626 ... Notch, 1627 ... Resistance connection groove, 1628 ... Condesor Groove for connection, 1631 ... Claw bearing, 1632 ... Claw bearing, 1633 ... Slit, 1635 ... End cap body outer edge, 17 ... Brush terminal structure, 170A ... Power supply terminal, 170B ... Relay terminal, 171 1 ... Terminal terminal, 171-2 ... Terminal terminal, 1715 ... Insertion part, 172 ... Brush holder, 173 ... Pigtail, 174 ... Brush, 175 ... Brush retainer spring, 176 (176-1,176-2) ... Connection terminal 177 ... Fixed claw part, 178 ... Step part, 179 (179-1,179-2) ... Connection terminal, 18 ... Shield cap, 1810 ... Shield cap body, 1801 ... Notch part, 1802 ... Notch part, 1812 ... Positioning part, 1813 ... Hole, 1814 ... Bearing holding claw, 1815 ... Bearing holding part, 1816 ... Positioning part, 19 ... EMC standard compliant noise prevention circuit, 191 ... Chalk coil, 192 ... Chalk coil, 193 ... One condeser (common mode), 194 ... resistor, 195a ... wiring, 195b ... wiring, 196a ... wiring, 196b ... wiring, 197 ... second condeser (normal mode), 198 ... wiring, 199 ... second bearing Interface holder, P1 ... connection terminal, P2 ... connection terminal, P3 ... terminal, P4 ... terminal, P5-P12 ... connection terminal.

Claims (11)

A magnet arranged on the inner peripheral side of the motor case, a rotor having an armature winding and a commutator, a pair of brushes in sliding contact with the commutator, and an end fixed to one end of the motor case to hold the brush. In a DC motor with a cap
The end cap
With the end cap body
A pair of brush holder holding portions provided at opposite positions on the surface side of the end cap main body and holding the pair of brushes,
Slits for terminals 1 to 4 provided near the outer edge of the end cap body and penetrating from the front surface side to the back surface side of the end cap body.
It is provided with a first choke coil holding groove and a second choke coil holding groove, respectively, provided between the pair of brushes on the surface side of the end cap body.
The first and second terminal / terminal slits are located at positions that sandwich the first choke coil holding groove, and the third and fourth terminal / terminal slits are located at positions that sandwich the second choke coil holding groove. Yes,
The planar shapes of the terminals 1 to 4 and the terminal slits are the same .
The end cap main body includes at least one condesor holding portion and at least one resistance holding portion, respectively, on the surface side of the end cap main body and radially outside the choke coil holding grooves. <br/> A DC motor with a brush that is characterized by this. The brushed DC motor according to claim 1, wherein each of the slits for terminals 1 to 4 has a slit portion and a claw receiving portion extending in the radial direction from both sides of the slit. .. A power supply terminal and a relay terminal corresponding to the slits for each terminal / terminal are provided.
The power supply terminal has a connection terminal, a step portion, a fixed claw portion, and a terminal terminal.
The relay terminal has a connection terminal, a step portion, a fixed claw portion, and an insertion portion.
The terminal terminal of the power supply terminal and the insertion portion of the relay terminal have the same cross-sectional shape that can be inserted into the slit portion of the terminal / terminal slit.
The brushed DC motor according to claim 2, wherein the fixed claw portion of the power supply terminal and the fixed claw portion of the relay terminal have the same cross-sectional shape that can be inserted into the claw receiving portion. .. The end cap
It is composed of the end cap body and the shield cap.
The brushed DC motor according to claim 1, wherein the shield cap has a bearing holding portion corresponding to a boss portion provided in a central portion of the end cap main body. The first brush and the second brush constituting the pair of brushes,
It is provided with a first relay terminal and a first power supply terminal corresponding to the first brush, and a second relay terminal and a second power supply terminal corresponding to the second brush.
The first brush is connected to the connection terminal of the first relay terminal,
The second brush is connected to the connection terminal of the second relay terminal,
The first relay terminal is fixed to the slit for the first terminal / terminal,
The second relay terminal is fixed to the slit for the third terminal / terminal,
The connection terminal of the first power supply terminal is connected to the slit for the second terminal / terminal,
The brushed DC motor according to claim 4 , wherein the connection terminal of the second power supply terminal is connected to the slit for the fourth terminal terminal. The first brush and the second brush constituting the pair of brushes are provided.
The first brush is connected to the connection terminal of the first power supply terminal,
The second brush is connected to the connection terminal of the second power supply terminal,
The first power supply terminal is fixed to the slit for the first terminal / terminal,
The brushed DC motor according to claim 4 , wherein the second power supply terminal is fixed to the slit for the third terminal / terminal. A second condenser holding portion is provided on the back surface of the end cap main body, and the second condenser is fixed to the second condenser holding portion.
The end cap body has a communication hole and
The brushed DC motor according to claim 5 , wherein the second condenser and the pair of power terminal connection terminals are connected by wiring through the communication holes. It is a manufacturing method of a DC motor with a brush.
The brushed DC motor includes a magnet arranged on the inner peripheral side of the motor case, a rotor having an armature winding and a commutator, first and second brushes that are in sliding contact with the commutator, and the motor case. With an end cap fixed to one end of the brush to hold each brush
The motor case, the magnet, the rotor, the first, second brush, and the end cap are both DC motor with noise suppression circuit, and common to the DC motor of the noise countermeasure circuit no It is a configuration to
The end cap has a pair of brush holder holding portions, first and second choke coil holding grooves, a resistance connecting groove, and a condesor connecting groove on the surface side of the end cap main body. A process of preparing a standard end cap structure having slits for terminals 1 to 4 penetrating from the front surface side to the back surface side of the end cap body near the outer edge of the end cap body.
The process of sandwiching the relay terminal from both sides of the end cap body and fixing it to the slits for the first and third terminals / terminals.
The process of sandwiching the power supply terminal from both sides of the end cap body and fixing it to the second and fourth terminal / terminal slits.
Wherein each brush holder holding portion, each said first, second brush, and a step of holding,
Each said first, second brush, as well as connected to the power supply terminal via the relay terminals, between the relay terminal and the power supply terminal, and a step of connecting said noise countermeasure circuit,
The first and second terminal / terminal slits are located at positions that sandwich the first choke coil holding groove, and the third and fourth terminal / terminal slits are located at positions that sandwich the second choke coil holding groove. A method of manufacturing a DC motor with a brush, which is characterized by being present. The power supply terminal and the relay terminal have a stepped portion and a fixed claw portion, respectively.
By applying the stepped portion to the surface of the end cap main body and pressing the fixed claw portion from the back surface side of the end cap main body, the power supply terminal and the relay terminal are sandwiched between both sides of the end cap main body. The method for manufacturing a DC motor with a brush according to claim 8 , wherein the DC motor is fixed to a cap body. The standard end cap structure, radially outward from the surface side a and the choke coil retaining grooves of the end cap body, the groove for the resistance connection, and has a groove for the Condesa connection,
A choke coil is connected between the relay terminal and each connection terminal of the power supply terminal on the surface side of the end cap main body.
Connect each end of the resistor and the condenser to the connection terminal on the power supply terminal side of the choke coil.
The method for manufacturing a brushed DC motor according to claim 9 , wherein the resistor and the other end of the condenser are connected to the motor case. The standard end cap structure has a second condessa holding portion on the back surface side of the end cap body, and has a communication hole that communicates between the front surface and the back surface of the end cap body.
The second condenser is fixed to the second condenser holding portion, and the second condenser is fixed.
Brush according to claim 9, characterized in that for connecting the second Condesa of the power source terminal and the relay terminal and the rear surface side of the surface side of the end cap body with a conductor through said communication hole Manufacturing method of DC motor with.

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