JPH0340738A - Manufacture of commutator - Google Patents

Abstract

PURPOSE:To manufacture a flat commutator with high workability by employing fan shaped element boards forming segment material and making slits radially in a ring type protective section chip plate. CONSTITUTION:A flat commutator 1 comprises a boss section 10 molded of resin into a thick disc, eight sets of segments 13 having fan shape and arranged circularly with same interval in the circumferential direction on one end face of the boss section 10, riser chips 4, and slits 12. The segment 13 comprises a copper base material 14, a protective section chip 15 composed of silver-nickel alloy and soldered to the contact point with a brush on the surface of the base material 14, and a pair of clicks 5, 5 for securing the segment 13 to the boss section 10. Tin galvanization coating 16 is applied onto the surface of the segment 13, and the galvanization coating 16 is removed from the outer face of the protective section chip 15 thus forming an exposed face 17.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a commutator, and in particular, a commutator piece in which a plurality of commutator pieces formed in a substantially fan shape are arranged radially, and each commutator piece is arranged in a radial manner. The present invention relates to a method for manufacturing a flat type commitake in which a protective piece is attached to at least a portion of the surface of the piece, and relates to a method that is effective for use in manufacturing a flat type commitake for countermeasures against gasohol, for example.

[Conventional technology]

When gasohol, which is gasoline mixed with alcohol, is used as a fuel, if the copper used in the fuel supply pump motor comes into contact with the gasohol, the fuel may be reformed or the copper may be eroded. Are known.

Therefore, as a countermeasure against gasohol, there is a commutator in which at least the surface of the W4 base material of the commutator segment (hereinafter referred to as segment) that comes into contact with the brush is clad with a protective piece made of a silver-nickel alloy. Examples of commitake for countermeasures against gasohol include Utility Model Application No. 60-135063 and Utility Model Application No. 62-1.
There are publications such as No. 32670.

Further, as a flat type commitake whose length in the axial direction is shortened, one is known in which a plurality of substantially fan-shaped segments are arranged radially and arranged in a circular ring shape. An example of such a flat type commitake is disclosed in Japanese Utility Model Publication No. 48-7362.

Therefore, as a flat type commitake for gasohol countermeasures,
A commutator in which a plurality of commutator pieces formed in a substantially fan shape are arranged radially, and a retaining piece is attached to at least a part of the surface of each commutator piece is designed for boat fishing. It will be done. As a manufacturing method for such a flat type gasohole countermeasure, Japanese Patent Application Laid-Open No. 59-72
It is conceivable to apply the technique described in Japanese Patent No. 961.

In other words, the manufacturing method of this flat type Comitake is limited to copper strip, which is the base material of the segment, and silver-2, which is the material of the protective piece.
a first step in which the copper strips or the silver-nickel alloy strips are formed by a drawing method; a second step in which a bonding material coating layer is deposited on the bonding surface side of at least one of the copper strips or the silver-nickel alloy strips; A third step in which a clad material is formed by joining the copper strip and a silver-nickel alloy strip with the bonding material coating layer as a boundary, and a crud material obtained in the third step is pressed. A fourth step in which individual segments are formed by punching out the segments to which the retaining parts are attached, and the individual segments are arranged in radial alignment in the cavities of the mold, and the resin is injected into the cavities. but? and a fifth step in which a disc-shaped boss portion is formed by forming the main part.

[Problem to be solved by the invention]

However, in the manufacturing method of flat type commitake for countermeasures against gasohol, since the clad material is formed into a strip shape, not only it is not possible to obtain approximately fan-shaped segments, but also it is necessary to mold individual segments formed in a rod shape. It is extremely difficult to align them radially on the mold.

An object of the present invention is to provide a method for manufacturing a commitake that can manufacture a flat commitake having substantially sector-shaped segments with good workability.

[Means to solve the problem]

In the method for manufacturing a COMITAKE according to the present invention, a plurality of commutator pieces each having a substantially fan-like shape are arranged radially, and a protective piece is attached to at least a part of the surface of each commutator piece. In the manufacturing method of Comitake, the base plate of the commutator piece has a plurality of trapezoidal pieces and riser pieces arranged alternately, and each trapezoidal piece is aligned in a straight line with the same orientation. a step of molding a blank plate arranged in a shape and integrally connected to each other and having a pair of claws protruding from both hypotenuses of the trapezoidal piece; There is a step of molding a protective piece plate having a ring shape with a width equal to or greater than the length of the trapezoidal piece in the blank of the base material, and a step of molding the protective piece plate on one end surface of the raw plate of the base material. The trapezoidal piece is arranged and welded so that it is along the normal line and the riser piece protrudes from the outer periphery of the protection plate, and the gap between this riser piece and the next trapezoidal piece is are separated, and then each trapezoidal piece is welded onto the protective piece plate.
a step of primary fixing each trapezoidal piece radially on one end surface of the protection piece plate; and housing the protection piece plate to which the group of trapezoidal pieces is fixed in a mold;
A process in which a boss part is integrally molded from a resin in which a group of trapezoidal pieces are implanted, and a protective part plate that is integrally molded on the boss part has multiple slits, and the trapezoidal part pieces are scaled together. the commutator segments are arranged in a radial manner and cut radially between the commutator segments, thereby forming a group of substantially fan-shaped commutator segments each having a protective piece attached to its surface. do.

[Effect]

According to the above-mentioned means, the trapezoid-shaped pieces of the blank plate forming the segment base material are formed in a substantially fan-shaped shape, and the slits are cut radially in the ring-shaped protection piece plate. Therefore, a flat commutator having a substantially fan-shaped segment group is manufactured.

In addition, since the boss part is resin-molded while the trapezoidal pieces are radially arranged and integrally fixed to the ring-shaped holding piece plate, the tree 11a shape work of the boss part is easy. It will be extremely simplified.

〔Example〕

FIG. 1 is an enlarged vertical cross-sectional view showing a commutator manufactured by a method for manufacturing a commutator according to an embodiment of the present invention, and FIG.
The following figures are explanatory diagrams for explaining the manufacturing method and operation thereof.

In this example, the method for manufacturing a commutator according to the present invention is used to manufacture a flat commutator that has a protective piece on the side that contacts the brush, and this flat commutator is shown in FIG. It looks like it's being worn out.

The flat commicator 1 shown in FIG.
and a plurality of sets (in this embodiment, for convenience of explanation and illustration, 8 sets are arranged in a circular ring shape and are formed into a substantially fan-shaped shape and are arranged at equal intervals in the circumferential direction on one end surface of the boss portion 10.
Let it be iIl. Hereinafter, the number of sets is the same, segment) 13, riser piece 4 integrated in each segment 13, and slit 12 for making adjacent segments 13 and 13 electrically independent are provided. The segment 13 has a base material 14 made of copper and a base material 1.
A protective piece 15 made of a silver-Nisokel alloy is welded to a contact point with a brush (not shown) on the surface of 4, and a pair of claws 5.5 for fixing the segment 13 to the boss part 10. We are prepared. A tin plating film 16 made of a metal such as tin that does not adversely affect gasohol is adhered to the surface of the segment 13, and the tin plating film 16 is removed from the outer surface of the protective piece 15. An exposed surface 17 is formed.

Hereinafter, one embodiment of the method for manufacturing the commutator according to the above structure will be explained, thereby clarifying the detailed interpolation of the flat commutator and its effects.

FIG. 2 is a partially omitted perspective view showing a base plate of a segment base material used for manufacturing a flat commutator.

In FIG. 2, the base plate 2 of the segment base material 14 is integrally formed into a substantially chain shape by press working using a copper-based material (body or copper alloy), and this base plate 2 has a narrow trapezoidal shape. A plurality of trapezoidal pieces 3 formed in the shape
and the same number of riser pieces 4 formed in a small rectangular shape. The trapezoidal pieces 3 and the riser pieces 4 are arranged integrally and alternately, with the trapezoidal pieces 3 oriented in the same direction and arranged in a straight line.

Each of the trapezoidal pieces 3 is formed in a trapezoidal shape that is slightly smaller than the segment, and is arranged at equal intervals in the length direction. Each riser piece 4 is interposed between adjacent trapezoidal pieces 3.3, and the trapezoidal pieces 3.
．． It is in a bad condition that 3 are connected to each other. Further, a pair of claws 5.5 are provided on both oblique sides of each trapezoidal piece 3 so as to protrude toward the end face on the opposite side to the side to which a protective piece plate (to be described later) is attached, and mutually. Each is bent so as to be inclined in the direction of approach.

FIG. 3 is a perspective view of a protective piece plate used for manufacturing a flat commutator having a protective piece.

In FIG. 3, the protective piece plate 6 for forming the protective piece 15 is integrally formed into a circular ring shape by press working using a silver-nickel alloy.
This protective piece plate 6 is formed in the shape of a large circular ring. The protective piece plate 6 formed into a wide ring shape is formed so that its outer diameter is approximately equal to the outer diameter of the flat commutator, and its inner diameter is approximately equal to the inner diameter of the segment group. has been done.

That is, the width dimension of the protective piece plate 6 is set to be slightly larger than the length of the trapezoidal piece 3 in the base material blank 2 and equal to the radial length of the segment.

FIG. 4 is a bottom view showing a joined structure formed by joining the base material blank shown in FIG. 2 and the protection piece plate shown in FIG. 3.

The bonded structure 8 shown in FIG. 4 is constructed such that each trapezoidal piece 3 of the blank plate 2 is aligned along the normal line on one end surface of the protective piece plate 6, and the live piece 4 is There are tI structures that are arranged so as to protrude from the outer periphery of the protective piece plate 6 and are fixed by spot welds 7. That is, this bonded structure 8 is manufactured as follows.

First, the leading trapezoidal piece 3 of the blank plate 2 is provided on one end surface of the protective piece plate 6 so as to extend along the normal line of the protective piece plate 6 and protrude from the long side of the trapezoid. The live pieces 4 are arranged so as to protrude radially from the outer periphery of the protection piece plate 6 and are brought into contact therewith.

Subsequently, electrodes (not shown) of a spot welding device are brought into contact with the protection piece plate 6 and the trapezoidal piece 3 that is in contact with one end surface of the protection piece plate 6, respectively, so that a gap is formed between the two parts 6 and 3. Welding power is applied. As a result, a spot weld 7 is formed between the protective piece plate 6 and the trapezoidal piece 3, so that the trapezoidal piece 3 is fixed onto one end surface of the protective piece plate 6.

When the trapezoidal piece 3 is fixed to the protective piece plate 6,
The riser piece 4, which is integrally connected to the fixed trapezoidal piece 3, is separated at the connection point with the trapezoidal piece 3 of the next stage.

The protective piece plate 6 is then rotated relative to one another by an angle of rotation corresponding to the pinching of the segments in the flat commutator. Then, the trapezoidal piece 3, which is the leading part after the riser piece 4 is separated, is placed first on the protective piece plate 6.
li! on one end face of ! The riser piece 4 is placed next to the trapezoidal piece 3 attached in the same manner as described above and fixed by spot welding, and the riser piece 4 is separated from the trapezoidal piece 3 at the next stage.

Thereafter, by repeating the operation, the trapezoidal pieces 3 and riser pieces 4 are radially arranged and fixed to the protection piece plate 6, and the three groups of trapezoidal pieces are arranged in a circular ring shape and fixed. Ru.

FIG. 5 shows a boss portion 11 attached to one end surface of the joint structure shown in FIG. FIG. 3 is a vertical cross-sectional view showing a state of forming.

The mold 20 used for this molding is an upper mold 21 and a lower mold 22.
The upper die 21 has a hollow disc-shaped cavity 23 having a diameter corresponding to the outer diameter of the commutator L, and a shape and arrangement of the riser pieces 4 extending horizontally from the outer periphery of the cavity 23. A groove portion 24 is formed in the radial direction so as to be formed, a core 25 is formed in the cavity 23 to form a shaft hole used to mount the commutator manufactured in this way on a rotating shaft, and a core 25 is formed in the cavity 23. It also includes a channel 126 for injecting resin as a material. Further, in the lower mold 22, a housing hole 27 formed in the shape of a disk hole having an outer diameter approximately equal to that of the protection piece plate 6 is provided in the cavity 23.
The protective piece plate 6 is fitted into the housing hole 27 to support and position the joining structure 8.

Then, the joined structure 8 formed by joining the trapezoidal piece 3 and the 4 groups of riser pieces and the protection piece plate 6 in the above step is formed by inserting the protection piece plate 6 into the accommodation hole 27 of the lower mold 22. It is inserted and set. Subsequently, when the upper mold 21 and the lower mold 22 are clamped together, the joining structure 8 is accommodated in the cavity 23, and the core 25 is arranged and inserted concentrically.

Thereafter, resin as a molding material is pumped into the cavity 23 from the gate 26 . Cavity 23 of this resin
By injecting into the resin, an integrally molded resin product 9 as shown in FIG. 6 is molded.

FIG. 6 is a perspective view showing the resin integrally molded product.

As shown in FIG. 6, a boss portion IO is integrally molded from resin on the end surface of the protective piece plate 6 of the bonded structure 8 on the side where the trapezoidal piece 3 is attached. A shaft hole 11 is opened on the center line of the portion 10 by a core 25.

FIG. 7 is a @ perspective view showing a state in which slits have been cut into the resin integrally molded product.

As shown in FIG. A plurality of slits 12 are arranged in the Lwh piece plate 6 at the center position between the adjacent trapezoidal pieces 3.3 and riser pieces 4.4, and a cutting tool (not shown) is arranged in the middle between the adjacent trapezoidal pieces 3.3 and riser pieces 4.4. These slits 12 are separated by cutting the protective piece plate 6 to a depth that reaches the boss 10, and the adjacent pieces are electrically connected. Each segment 13 is substantially independent of the other. That is, the segment 13 includes a protection piece 15 and a base material 14 that are separated from each other by a slit 12, and the base material 14 has a riser piece 4 and a pair of claws 5.5.
are integrally connected.

The pair of claws 5.5 are embedded within the boss 10 to ensure that the segment 13 is integrated with the boss 10.

After that, by ventilation means such as de-plating, etc.
A tin plating 11116 is applied to the surface of each segment 13 as shown in FIG.

This tin plating film 16 is deposited to prevent the gear from being exposed in fuel such as gasohol, thereby preventing reformation of the fuel and improving the durability of the commutator. .

Next, as shown in FIG. 9, the tin plating film L6 deposited on the protective piece 15 is removed by an appropriate means using a cutting tool or the like, so that the sliding surface with the brush is removed. An exposed surface 17 is formed on the surface of the protective piece 15 . Since the protective piece 15 is made of a sheet-nickel alloy, it does not interfere with gasohol and has high abrasion resistance.

In this way, a flat commutator having a protective piece as shown in FIG. 1 mentioned above was created.

Note that the present invention is not limited to the above embodiments,
It goes without saying that various changes can be made without departing from the gist of the invention.

For example, the method for manufacturing a commutator according to the present invention is not only applicable to a method for manufacturing a flat commutator for gasohol counters, but also for other general methods for manufacturing a flat commutator. Therefore, the material of the base material and the material of the protective piece are not limited to the above embodiments.

〔Effect of the invention〕

As explained above, according to the present invention, the following effects can be obtained.

(1) The trapezoid-shaped piece of the blank plate that forms the segment Ill material is formed into a substantially fan-shaped shape, and the slits are cut radially in the ring-shaped protection piece plate, so that it is shaped like a substantially fan-shaped part. A flat commutator having a group of shaped segments can be manufactured.

(3) Since the boss part is resin molded with each trapezoidal part arranged radially and integrally fixed to the ring-shaped holding part plate, the resin molding work of the boss part is easy. It will be extremely simplified.

(3) The amount of segment base material used can be reduced.

[Brief explanation of drawings]

FIG. 1 is a longitudinal sectional view showing a commutator manufactured by a method for manufacturing a commutator according to an embodiment of the present invention, and FIGS.
Fig. 9 is for explaining the manufacturing method and operation thereof, Fig. 2 is a perspective view showing a base plate of the segment base material used for manufacturing the flat commutator, and Fig. 3 is a view showing the base plate of the segment base material used for manufacturing the flat commutator. A perspective view showing a protective piece plate used in the manufacture of a flat commutator, FIG. 4 shows the connection between the base material plate shown in FIG. 2 and the protective piece plate shown in FIG. 3. Fig. 5 is a vertical cross-sectional view showing a state in which a boss portion is molded with resin on one end surface of the joined structure shown in Fig. 4, and Fig. 6 is a bottom view showing a joint structure formed by resin molding. Fig. 7 is a perspective view showing a state in which slits have been cut into a resin integral molded product, and Fig. 8 is a perspective view showing a state in which a film has been applied to the surface of the segment. ji and FIG. 9 are longitudinal sectional views showing a state in which a portion of the coating has been removed. DESCRIPTION OF SYMBOLS 1... Flat commutator, 2... Segment base material plate, 3... Trapezoidal piece, 4... Riser piece, 6...
・Protective part plate, 7... Spot welded part, 8...
-Joint structure, 9...Resin integrally molded product, 10...Boss portion, 11...Shaft hole, 12...Slit, 13...
・Segment, 14... Segment base material, 15...
Protective piece, L6...Tin plating film, 17...Exposed surface of protective piece, 2o...Made by molding, 21...Upper mold, 22
... Lower mold, 23 ... Cavity, 24 ... Groove, 25 ... Core, 26 ... Gate, 27 ... Protective piece plate accommodation hole. Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8

Claims (1)

[Claims] 1. A commutator in which a plurality of substantially fan-shaped commutator pieces are arranged radially, and a protective piece is attached to at least a part of the surface of each commutator piece. In the manufacturing method, in the base plate of the commutator piece, a plurality of trapezoidal pieces and riser pieces are arranged alternately, and each trapezoidal piece is aligned in a straight line. a step of molding blank plates that are arranged side by side and integrally connected and each having a pair of claws protruding from both oblique sides of the trapezoidal piece; and the blank plate of the protection piece, , forming a protective piece plate having a ring shape with a width equal to or longer than the length of the trapezoidal piece in the blank of the base material; and forming a trapezoidal shape of the blank on one end surface of the protective piece plate. The pieces are arranged and welded so that they are along the normal line and the riser piece protrudes from the outer periphery of the protective piece plate, and the riser piece and the next trapezoidal piece are separated. Thereafter, each trapezoidal piece is welded onto the protection piece plate, and each trapezoidal piece is sequentially fixed radially on one end surface of the protection piece plate; A step in which the protective piece plate to which the group is fixed is housed in a mold, and a boss made of resin having the trapezoidal piece group implanted therein is integrally molded; A plurality of slits are arranged in the protection piece plate and are cut radially between adjacent trapezoidal pieces, so that the commutator has a generally fan-shaped shape and has a protection piece attached to its surface. A method for manufacturing a commutator, comprising the step of forming a group of pieces.