JPH01676A - Brush assembly manufacturing method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to brush assemblies that are widely used for transmitting electrical signals in combination with resistors, slip rings, etc., such as potentiometers, trimmers, and encoders. The present invention relates to a method for manufacturing lees.

[Conventional technology]

A method of manufacturing a brush assembly by arranging a large number of thin wires in parallel in a horizontal state and welding them to a substrate is already known, as described, for example, in Japanese Patent Publication No. 16718/1983.

Generally, when feeding the wire in a horizontal state, the width of the groove for inserting the wire provided in the wire feeding jig is made slightly wider than the width of the completed brush so that the wire can be fed somewhat smoothly and without resistance. Since the wires are insulated, gaps are created between the wires. Therefore, there is a problem in that the width of the completed brush varies. Also, if there is a gap between the wires,
There is a problem in that during welding, electricity is not applied uniformly, resulting in local conductive overheating, and molten material flows into the gap, causing the brush to come apart. Moreover, it is almost impossible to detect parts where such flow has occurred during continuous production, and if they are incorporated into equipment as an assembly without being discovered in the subsequent process, it may cause problems during the operation of the product being used. The molten material may fall and cause secondary accidents such as damage to the product being used and short circuits in internal circuits.

On the other hand, as a method for welding wire rods consisting of a large number of thin wires in parallel alignment in a horizontal state without creating gaps between the thin wires, tension is applied to each thin wire so that it does not bend. Stress is applied to the heat generating part of the
Inconveniences such as stress cracking and falling off of the wire are likely to occur.

[Problem that the invention seeks to solve]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a method for manufacturing a brush assembly that can be welded so that no gaps are formed between the thin wires, and that does not cause problems such as stress cracking or falling off of the wires.

[Means for solving problems]

The present invention is based on the knowledge that if a wire consisting of a large number of thin wires is welded after being inserted into a projection recess provided on a substrate, it can be welded to the substrate without any gaps between the thin wires, and the above problem can be efficiently solved. It was done based on.

That is, the present invention is a method for manufacturing a brush assembly made by welding a wire rod consisting of a large number of thin wires to a substrate,
After synchronously transporting the wire and the substrate and aligning the wire in parallel to the projection recess provided on the substrate,
A method for manufacturing a brush assembly is provided, which comprises welding a wire to a substrate.

Next, a method for manufacturing a brush assembly according to the present invention will be explained using an example. FIG. 2 shows an enlarged schematic view of the brush assembly substrate 1 used in the present invention, and a projection 3 is formed on the crosspiece 2 of the substrate 1. The present invention is particularly characterized by using a projection in which a recess is formed on the projection. This recess is shown in Figure 1, and the diameter is 1.
A cross-sectional view is shown in which a wire rod 5 consisting of six thin wires 4 of 20 μm is mounted. Here, the projection 3 is the crosspiece 2 of the substrate 1.
It is best to form it at a height of 30 to 50 μm on top.
It is preferable that the angle of the recess 6 is 120 degrees, the pitch interval is almost the same as that of the thin wire 4, and the depth of the recess is about 30 μm. In the present invention, as shown in FIG.
It is preferable that the shape is such that the zero recess 6 contacts each thin wire 4 at at least two points. Therefore, as such an embodiment, partially enlarged sectional views of the projection are shown in FIGS. 3 to 5. Alternatively, a protrusion may be provided on the crosspiece 2 so as to protrude toward the hole aB7 of the substrate 1 shown in FIG. 2, and the projection 83 may be formed on the protrusion. Forming the recesses on the above-mentioned projectimin can be easily performed by a known method, for example, by pressing or the like.

Next, a method of manufacturing the brush assembly of the present invention using the substrate 1 will be explained using one embodiment. FIG. 6 shows a schematic diagram of the method for manufacturing the brush assembly of the present invention, in which a wire rod 5 consisting of seven thin wires each having a diameter of 120 μm is supported by a guide 8, and is fed at a constant speed and fed to a close alignment device 9. - Transported in a time-stop cycle. The close alignment device 9 closely aligns the plurality of thin wires so that they are tightly aligned in the projection recess when they are stacked on the substrate in the 11th step. On the other hand, separate from the wire rods 5, the continuous substrates 1 pass through the substrate guide lO, and are sequentially fed out parallel to the alignment plane of the wire rods 5 that are closely aligned in parallel, and in conjunction with the cyclic motion in which the wire rods 5 are fed out.

The wire rod 5 and the substrate l, which are fed out in conjunction with each other, overlap and become one body during the transfer, and for example, as shown in FIG. It is inserted between the recesses 6. Therefore, according to this method, the thin wires can be easily brought into close contact with each other and there is no gap between the thin wires 4. Next, the substrate feed roller 1
1 to a welding device 12. Incidentally, it is preferable that the wire rod 5 and the substrate 1, which are fed out in conjunction with each other, enter the welding device 12 after being stopped once. As shown in FIG. 8, the welding device 12 is installed so that the upper electrode 13 and the lower electrode 14 are parallel to the wire surface. When the projection part 3 of the substrate 1 stops below the upper electrode 13 of the welding device 12, the upper electrode 13 descends, the substrate 1 is pressed, and the thin wire 4 is welded onto the lower electrode 14. A closely aligned thin wire 4 is welded to the projection part 3.

At this time, according to the present invention, the thin wires are in close contact with each other, and even when pressed by the lowering of the upper electrode 13, the thin wires are firmly fixed in the recesses, so the thin wires do not shift, and this is extremely efficient. It has the advantage of being weldable. Thereafter, the substrates 1 to which the wire rods 5 have been welded are sequentially transferred and wound onto a winding roll 15. FIG. 7 is a schematic view of this manufacturing process seen from above.

In the above embodiment, the continuous substrate 1 is sent out above the close parallel alignment wire 5, but in some cases, the continuous substrate 1 is sent out below the alignment wire 5, the upper electrode 13 is lowered, and the alignment wire 5 is sent out to the projection 3 of the substrate 1. The welding may be performed by pressing into the recess 6 provided in the.

In addition, in the present invention, as the thin wires constituting the wire material 5, wires having various diameters, for example, 60 to 150 μm, can be used, and the number of wires arranged is not limited to seven, for example, 1.
It can be used with 0, 80, etc.

In the present invention, wire rods made up of a large number of thin wires can be aligned almost horizontally and welded to a substrate. 15-90°, preferably 30-4
It is also possible to weld the thin wire to a substrate which is brought into close contact with the wire at an inclination angle of 5° and is transferred in synchronism with the wire.

The brush assembly manufactured in this manner has the ninth
As shown in the figure, after cutting the wire 5, the tip of the cut wire is bent, and then both ends of the crosspiece are cut to be used, for example, as a sliding brush.

〔Effect of the invention〕

According to the present invention, the thin wires constituting the wire rod can be easily welded to the substrate without using any special equipment, with the thin wires being in close contact with each other and without any gaps between the thin wires. Further, since the thin wire does not shift from a predetermined position on the projection during welding, the thin wire can be welded onto the projection with high accuracy.

Therefore, it is possible to efficiently prevent the brush from coming loose, adhering to unnecessary welding materials, etc. Furthermore, by applying Teflon coating to the wire contact surface of the close alignment device, damage to the wire and the substrate can be prevented and smooth transfer is possible.

[Brief explanation of the drawing]

FIG. 1 is an enlarged cross-sectional view showing thin wires constituting a wire rod aligned in a projection recess for a brush assembly used in the present invention shown in the A-A cross-sectional view in FIG. 2; FIG. 32 is a schematic diagram of a substrate for a brush assembly used in the present invention. FIG. Figure 7 is a schematic diagram showing the manufacturing process of the brush assembly of the present invention.
The drawings are a top view of FIG. 6, FIG. 8 is a schematic sectional view of the welding device, and FIG. 9 is a diagram showing the manufacture of a sliding brush. In the figure, ■ is the board, 3 is the projection, 5 is the wire, and 6
9 is a concave portion, 9 is a close alignment device, 12 is a welding device, 13 is an upper electrode, and 14 is a lower electrode. Figure 1 Figure 2 Figure 3 Figure 4 Figure 8

Claims (4)

[Claims] (1) A method for manufacturing a brush assembly made by welding a wire consisting of a large number of thin wires to a substrate, in which the wire and the substrate are synchronously transferred and the wires are aligned in parallel in a projection recess provided on the substrate. A method for manufacturing a brush assembly, comprising: welding the wire to the substrate after the (2) The method according to claim 1, wherein the welding is performed using a close-pressing device that applies a force parallel to a plane formed by the wire rods and welds the wire rods in close contact with each other. (3) The method according to claim (1), wherein the projection is provided on a crosspiece between the holes of the substrate. (4) The method according to claim (1), wherein the projection recess is shaped so that it contacts each wire at at least two points.