JPH05198341A - Commutator for rotational electric machine - Google Patents

Abstract

PURPOSE:To provide a commutator inexpensive and suitable for mass production and to utilize a material perfectly. CONSTITUTION:In the widthwise direction of a band-like conductive plate 15, wires 16 of the same number as segments are conductively connected by welding at an equal interval, and the band-like conductive plate is rounded to direct the wires in the inner radial direction so as to form an annular conductor. The wires 16 together with the annular conductor are molded by a molding material 17, the annular conductor is undercut to be divided into segments so as to form a commutator, which is inexpensive and suitable for mass production and prevents floating of the wires by means of molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a commutator for a rotary electric machine, which is inexpensive and suitable for mass production.

[0002]

2. Description of the Related Art Conventionally, in order to mass produce commutators,
A method has been adopted in which a thick copper pipe is annealed, and this material is cold forged to simultaneously form a segment groove and a riser portion, and form this into a commutator by molding.

Further, in the case of a commutator having a small diameter, a method is adopted in which a copper plate is used for punching and bending to prevent a segment from coming off and a riser portion to be formed, and then molded to form a commutator. These methods are disclosed, for example, in Japanese Examined Patent Publication No.
No. -40940 and Japanese Utility Model Publication No. 63-9257.

In the method using the copper pipe, the copper pipe is expensive and the annealing takes a long time.
Moreover, the method of punching a copper plate is inexpensive and suitable for mass production, but in the case of a high-speed rotary machine, the central portion of the segment swells due to centrifugal force, which is the cause of the brush. Further, since the copper plate is punched out to form the segment retainer and the riser portion, a large amount of scraps are produced and the material is wasted.

Here, a conventional example will be described with reference to the drawings. 11 to 14 are views showing the structure of a conventional commutator. First, in the case of FIG. 11, an annular body before molding which is processed from a copper pipe is shown. 1 in FIG. 11 is an annular body. The ring-shaped body 1 is made by annealing a copper pipe, putting it in a die, and pressurizing it.

In the case of FIG. 12, the annular body 1 is molded,
13 is a cross-sectional view of a commutator, and 5 in FIG. 12 is a mold, which holds the segment portion 2 and the bush 6. In the case of the structure of FIG. 12, a thick copper pipe is required, and the copper pipe must be annealed so that it can be easily cut and processed.

Further, in the case of FIG. 13, it is made by punching out a copper plate, and 7 in the figure is a segment portion, 8,
Each of 9 and 10 is bent as shown in FIG. Reference numeral 10 constitutes a riser. In the case of FIG. 10, a single copper plate is punched out to form the riser 10, the segment portion 7 and the retaining member, so that it is widely used for small-sized low-speed rotating electric machines in an advantageous manner.

[0008]

When this structure is used in a high-speed rotating electric machine, the center portion of FIG. 14 where the mold and the segment portion have the least contact swells to cause brush dancing. Moreover, since the riser 10 winds the armature winding, it is necessary to chamfer the wire in order to prevent disconnection. In this method, since the retainers 8, 9, 11 and the riser 10 are projected from the segment portion 7, there is a drawback that a large amount of scraps are produced and the material cost is increased accordingly. This is because if the armature winding diameter is large, the riser 10 is made high, and the material removal becomes worse.

The invention set forth in claim 1 has been made to solve the above problems, and an object thereof is to obtain a commutator for a rotary electric machine which is inexpensive and suitable for mass production.

According to the second aspect of the present invention, there is provided a commutator for a rotating electric machine, which can withstand centrifugal force during high-speed rotation and can be easily applied to models having different riser structure. To aim.

Further, an object of the present invention is to obtain a commutator for a rotating electric machine which can be easily coped with by changing the size of the terminal even in a model in which the winding diameter of the armature winding is different. To do.

Further, according to the invention described in claim 4,
An object is to obtain a commutator for a rotating electric machine that can endure high-speed rotation.

[0013]

A commutator for a rotating electric machine according to a first aspect of the present invention has a number of wire rods arranged in a widthwise direction of a belt-shaped conductive plate at a predetermined interval so as to electrically contact each other. An annular conductor is provided which is annular and is molded with a molding material together with the wire.

In the commutator of the rotating electric machine according to the second aspect of the invention, the wire rod is elongated to form the riser of the commutator.

A commutator for a rotating electric machine according to a third aspect of the present invention is such that a terminal molded with a molding material is provided at one end where the wire is made longer than the width of the belt-shaped conductive plate.

A commutator for a rotating electric machine according to a fourth aspect of the present invention holds a wire rod having a length longer than the width of the belt-shaped conductive plate and electrically conductively bonded to the belt-shaped conductive plate, and holding both ends of the wire rod. And an insulator.

[0017]

According to the first aspect of the present invention, the same number of wire rods as the number of the segments are conductively adhered to the strip-shaped conductive plate in the width direction to form a ring-shaped conductor, which is molded into 1 piece per segment.
By undercutting the annular conductor so as to have a wire rod, the commutator is divided into segments and the adhesive force between the wire rod and the molding material works strongly over the entire length of the wire rod, and at the time of high-speed rotation. Also suppresses the floating of the segment.

According to the second aspect of the present invention, since the one end of the wire is extended to form the riser portion, the armature winding is cut even if the end portion of the armature winding is wound around the riser portion. It acts so as not to be.

According to the third aspect of the present invention, when one end of the wire is extended to hold the armature winding on the terminal molded with the molding material, and the winding diameter of the armature winding is different, This can be handled by changing the vertical dimension of the terminal.

In the invention as set forth in claim 4, since both ends of the wire are held by the insulating material and the whole is molded, the centrifugal force applied to the segment at the time of high speed rotation is endured by the wire, the mold and the insulator. To work.

[0021]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of a commutator for a rotary electric machine of the present invention will be described below with reference to the drawings. FIG. 1 shows the first of the present invention.
15 is a plan view of the strip-shaped conductor of the embodiment of the present invention, in which 15 is a strip-shaped conductive plate, which is formed of, for example, a copper plate, and the strip-shaped conductive plate 15 has a copper wire rod 16 as a wire rod similar to the segment. Are welded at a predetermined interval (segment interval). As a result, the copper wire 16 and the strip-shaped conductive plate 15 are electrically conductive.

In this state, the strip-shaped conductive plate 15 is replaced with the copper wire 16
Is bent in a ring shape so as to face the center direction to form a ring-shaped conductor as shown in FIG. This FIG. 2 is a half-cut sectional view, and as is clear from FIG. 2, one copper wire rod 16 is annularly arranged for each segment on the inner peripheral surface of the annular conductor.

In this state, the copper wire material 16, the bush 18 and the annular conductor are molded by the molding material 17, and the annular conductor is undercut at the undercut portion A in FIG. Divided into segments, commutators are formed.

With this structure, the wire rod is composed of the copper wire rod 16 and the strip-shaped conductive plate 15 made of a copper plate, and since there is no complicated machining, it is inexpensive and suitable for mass production. Since there is no processing, punching residue does not occur, the material can be used 100%, and the molding material 17 is provided over the entire length of the copper wire rod 16.
Due to the strong adhesion, the segment does not float even during high-speed operation.

FIG. 3 is a cross sectional view showing the structure of the second embodiment of the present invention, and is a cross sectional view when completed as the commutator shown in FIG. In the second embodiment of FIG. 3,
The riser 16a is formed by bending one end of the copper wire rod 16. By forming the riser 16a in this manner, when the commutator rotates at high speed, the centrifugal force received by each segment is the adhesive force between the copper wire 16 and the molding material 17,
That is, it depends on the intensity of the portion B in FIG. Since the portion B exists over the length in which the copper wire 16 is embedded in the mold 17, even if the commutator rotates at a high speed, it can sufficiently withstand the centrifugal force.

Furthermore, in order to withstand a large centrifugal force, the copper wire 16 may be made larger than the width of the strip-shaped conductive plate 15. That is, it may be extended like the portion C in FIG. In the embodiment of FIG. 3, the copper wire 16 is bent as it is to form the riser portion 16a. Therefore, even if the end portion (not shown) of the armature winding is wound around the riser portion 16a, the armature winding 16a is wound. Will never be disconnected.

Further, also in the case of the second embodiment, as in the first embodiment, the strip-shaped conductive plate 15 and the copper wire 16 are provided.
Is welded conductively only by welding, and machining such as machining, which does not produce chips and burrs, is performed. A layer short circuit can be prevented and productivity can be improved.

Further, in the first and second embodiments, the commutator having a large number of segments may be formed by reducing the welding interval of the copper wire rods 16, and those having different commutator diameters may be strip-shaped conductive plates 15. You can change the length of.

Next, a third embodiment of the present invention will be described. FIG. 4 is a plan view of the third embodiment. In the case of the third embodiment of FIG. 4, in a motor in which a large current flows, such as an automobile starter motor, the armature winding diameter is This is a solution to the need to make the riser section larger because it becomes thicker.

That is, as shown in FIG. 4, the wire rods 20 and the belt-like conductive plate 19 are conductively welded by arranging and welding the wire rods 20 on the belt-shaped conductive plate 19 at equal intervals. As is apparent from the perspective view of FIG. 5, one end of this wire 20 is
The terminal 21 formed in a "U" shape is welded and welded.

As shown in FIGS. 6 and 7, the belt-shaped conductive plate 19 is welded to the belt-shaped conductive plate 19 and the belt-shaped conductive plate 19 is rolled into an annular conductor. Commutator. FIG. 7 is a sectional view. Reference numeral 22 in FIG. 7 denotes a mold material, and the wire material 20 and the strip-shaped conductive plate 19 are molded by the mold material 22. In addition, 23 has shown the bush.

FIG. 6 is a sectional perspective view of the portion of the terminal 21 shown in FIG. As is clear from FIG. 6, the terminal 21 is held by the mold 22, and the thick armature winding is connected to the terminal 2.
1 is enough hold. The third embodiment shown in FIGS. 4 to 7 can easily cope with models of different armature winding diameters, that is, different motor capacities only by changing the dimension (vertical direction) of the terminal 21. be able to.

8 to 10 show a fourth embodiment of the present invention. FIG. 8 is a plan view of the wire rod 2 having the same number of segments as the number of segments in the width direction of the strip-shaped conductive plate 25.
4a to 24d (hereinafter, collectively referred to as a wire rod 24) are welded and welded. The wire rod 24 is longer than the width of the strip-shaped conductive plate. The wire rod 24 is a strip-shaped conductive plate 25.
By rolling the strip-shaped conductive plate 25 in the state of being welded to
As shown in FIG. 10, an annular conductor is formed, and the wire 24 is arranged on the inner peripheral surface of this annular conductor.

FIG. 9 is a sectional view thereof. As is clear from FIG. 9, the wire 24 and the strip-shaped conductive plate 25 are molded, and the molding temperature of the molding material 27 is 160 ° C.
In order to withstand the above high temperature, the insulator 26 is annular and has through holes or blind holes 26a, 26a as shown in FIG.
b, 26c, 26d ... Are formed. Wires 24 are inserted into these through holes or blind holes 26a to 26d.

Then, as shown in FIG. 9, the insulator 26 is inserted on both sides of the wire 24 with the strip-shaped conductive plate 25 sandwiched therebetween. One end of the wire 24 is bent to form a connection terminal 24a to the armature winding. In addition, 28 is a bush. After this structure, the annular conductor is undercut to separate the strip-shaped conductive plate 25 into segments.

In the fourth embodiment, the centrifugal force applied to the segment at the time of high speed rotation is endured by the wire rod 24, the molding material 27 and the insulator 26. If the temperature of the segment becomes high, the strength of the molding material 27 is reduced, and the insulator 26 is mainly used to withstand the centrifugal force. In this case, the centrifugal force applied to the central portion of the segment is taken up by the wire rod 24 as the skeleton of the segment, so that the segment 24 withstands high centrifugal force.

[0037]

As described above, according to the first aspect of the present invention, the same number of wires as the number of segments are bonded to the strip-shaped conductive plate, and the bonding surface of the wires is formed into an annular shape so that the bonding surface is in the inner diameter direction. Since it is configured as an annular conductor and molded with a molding material, the material can be composed of a strip-shaped conductive plate and a wire material, and since there is no complicated machining, there is no punching residue, so the material can be used 100%. It is inexpensive and suitable for mass production. Further, since the adhesive force between the wire and the molding material works strongly over the entire length of the wire, the segment does not float even during high-speed rotation.

Further, since the commutator model can be changed by a simple change such as the change of the bonding interval of the wire material and the change of the length of the strip-shaped conductive plate, it is possible to deal with a wide variety of products in a small amount at a low cost.
Further, since the band-shaped conductive plate and the wire are simply adhered and there is no processing such as cutting to produce chips, layer shorts between segments at the time of completion of molding can be eliminated and productivity can be improved.

According to the second aspect of the invention, since the wire rod is extended to form the riser portion, it is possible to easily cope with a model having a different riser portion structure.

According to the third aspect of the present invention, the wire is extended, the terminal is provided at one end, and the armature winding is held at this terminal. Therefore, the armature winding is sufficiently held. In addition to the above, the present invention has an effect that even models having different winding diameters of the armature winding can be easily dealt with by simply changing the vertical dimension of the terminal.

Further, according to the invention of claim 4,
Form a wire longer than the width of the strip-shaped conductive plate and bond it to the strip-shaped conductive plate, then roll this strip-shaped conductive plate into an annular conductor, hold both ends of the wire with insulators, and mold the whole with a molding material. With this configuration, the centrifugal force applied to the segment during high-speed rotation is withstood by the wire rod, the molding material, and the insulator, which has the effect of having a high centrifugal force resistant model.

[Brief description of drawings]

FIG. 1 is a plan view of a part of a commutator of a rotary electric machine according to a first embodiment of the present invention.

FIG. 2 is a half cutaway view of the first embodiment.

FIG. 3 is a sectional view of a commutator of a rotary electric machine according to a second embodiment of the present invention.

FIG. 4 is a plan view showing a part of a commutator of a rotary electric machine according to a third embodiment of the present invention.

FIG. 5 is a perspective view of a wire rod applied to the third embodiment.

FIG. 6 is a perspective view showing a cross section of a terminal portion in the third embodiment.

FIG. 7 is a sectional view showing a configuration of a third embodiment of the same.

FIG. 8 is a plan view showing a part of a commutator of a rotary electric machine according to a fourth embodiment of the present invention.

FIG. 9 is a transverse cross-sectional view showing the configuration of the above-mentioned fourth embodiment.

FIG. 10 is a front view of an insulator according to the fourth embodiment.

FIG. 11 is a plan view of an annular conductor applied to a commutator of a conventional rotating electric machine.

FIG. 12 is a cross-sectional view of a commutator of a conventional rotating electric machine that uses the annular conductor of FIG.

FIG. 13 is a plan view of a segment portion applied to a commutator of another conventional rotating electric machine.

14 is a cross-sectional view of a commutator of another conventional rotating electric machine that uses the segment of FIG.

[Explanation of symbols]

 15 band-shaped conductive plate 16 copper wire 16a riser 17 molding material 18 bush 19 band-shaped conductive plate 20 wire 21 terminal 22 mold material 23 bush 24 wire rod 25 band-shaped conductive plate 26 insulator 27 mold material 28 bush

Front page continuation (72) Inventor Takeyoshi Nishihara 640 Funasaka, Kamigori-cho, Ako-gun, Hyogo Kobishi Electric Co., Ltd.

Claims (4)

[Claims] 1. A ring-shaped conductive member in which a wire-shaped conductive plate is conductively adhered to the inner surface of a ring-shaped conductive plate in the widthwise direction at the same number of segments as the number of segments and undercut to form segments. A commutator for a rotating electric machine, comprising a body, a molding material for molding the wire and the annular conductor. 2. The commutator for a rotary electric machine according to claim 1, wherein the wire is elongated and one end thereof is used as a riser of the commutator. 3. The commutator for a rotary electric machine according to claim 1, wherein the wire has a terminal molded with the molding material at one end which is longer than the width of the belt-shaped conductor. 4. The wire according to claim 1, wherein the wire is made longer than the width of the strip-shaped conductor, and both ends of the wire are held by insulators and the whole is molded with a molding material. Commutator of rotating electric machine.