JPH11275819A - Rotor and commutator of direct-current motor and manufacture of the rotor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the reliability of connection between windings and commutator pieces. SOLUTION: In the rotor of the direct-current motor, a commutator comprising a plurality of salient poles and a plurality of commutator pieces is installed around a center shaft, and windings 5 wound around the pole cores of the salient poles are connected with the commutator pieces 2a via hooked hardware 6a, 6b. The winding housing portion of the hooked hardware 6a, with which the start 5a and end 5b of the windings 5 are connected, is so formed that the winding housing portion of the hooked hardware 6a is deeper than the winding housing portions of the other hooked hardware 6b by an amount equivalent to one piece of the winding. Hook ends 8a, 8b of all the hooked hardware 6a, 6b are deformed under pressure into almost the identical same shape, and connections between the windings 5 and the hooked hardware 6a, 6b are electrically welded. The rotor is manufactured so that in the hooked hardware 6b housing the intermediate portions of the windings 5 and the hooked hardware 6a housing the start 5a and end 5b of the windings 5, the outermost faces of the windings 5 are positioned at almost the same points on the center shaft in the lengthwise direction.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotor and a commutator of a DC motor and a method of manufacturing the rotor, and more particularly to a method of improving reliability of a connection between a winding and a commutator. is there.

[0002]

2. Description of the Related Art Conventionally, a rotor of a DC motor is provided with a commutator including a plurality of salient poles and a plurality of commutator pieces around a central axis, and a winding is wound around a pole core of the salient pole at a predetermined number of times. Each salient pole is manufactured to have a structure in which a winding is connected to a corresponding commutator piece. The connection between the winding and the commutator piece is performed by a method in which a hook-shaped metal piece is provided on the commutator piece, the winding is accommodated in a winding accommodating portion of the hook-shaped metal piece, and the part is press-deformed and electrically welded. ing.

[0003]

In the structure of the rotor and the method of manufacturing the same as described above, the hook-shaped hardware provided on each commutator piece has the same shape and the same structure. The number of windings accommodated for connection is different between the hook-shaped metal body to which both ends of the winding start end and the winding end end are connected, and the hook-shaped metal body to which the middle part of the winding is connected, and the pressure deformation is caused. There has been a problem that the condition of the portion to be electrically welded becomes non-uniform and a highly reliable connection cannot be made.
At present, a single type of electrode is used as the electrode to be pressed for electric welding, so that the pressing pressure is strong in the hook-shaped metal part that accommodates both ends of the winding start end and winding end. The windings caused fusing, fatigue, and separation of the windings. In addition, in the hook-shaped metal part accommodating the intermediate part of the winding, welding was insufficient and electric conduction failure occurred. In order to avoid these inconveniences, both the shape of the electrode for electrodeposition and the pressure are adjusted to achieve matching. However, in reality, satisfactory results have not been obtained.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to provide a rotor of a DC motor, a commutator, and a method of manufacturing the rotor, in which the connection between a winding and a commutator piece is highly reliable. The purpose is.

[0005]

SUMMARY OF THE INVENTION The present invention has been made based on the above-mentioned object, and has a configuration in which the shape of a hook-shaped metal member provided on a commutator piece is changed in accordance with a portion of a winding to be connected. is there.

That is, according to the first aspect of the present invention, a plurality of salient poles and a commutator composed of a plurality of commutator pieces are provided around a central axis, and the winding wound around the pole core of the salient pole is a commutator. In a rotor of a DC motor connected to a piece via a hook-shaped metal piece, a winding-receiving portion of a hook-shaped metal piece to which both ends of a winding start end and a winding end end of the winding are connected has another hook shape. The hook ends of all hook-shaped metal parts are formed deeper than the wire winding receiving part, and the hook ends of the hook-shaped metal parts are pressed and deformed into substantially the same shape, and the connection part between the winding and the hook-shaped metal parts is electrically welded. And a rotor of the DC motor.

According to a third aspect of the present invention, there is provided a commutator comprising a plurality of commutator pieces mounted around a central axis of a rotor of a DC motor, wherein a salient pole core provided around the central axis is provided. A hook-shaped metal member is provided for each commutator piece for connecting the winding wound around the winding, and a hook-shaped metal member for connecting both ends of a winding start end and a winding end end of the winding is provided. The housing portion is formed deeper than the winding housing portion of the hook-shaped metal for connecting the intermediate portion of the winding, and in the longitudinal direction of the central axis, the outermost surface of the winding housed in each winding housing portion is formed. A commutator for a DC motor, wherein the commutator is arranged at substantially the same position.

Further, according to the present invention, a winding is wound around the pole cores of a plurality of salient poles provided around a central axis, and a winding is provided around the central axis for each salient pole. In the method for manufacturing a rotor of a DC motor, which is connected to a corresponding commutator piece of a commutator, the connection between the winding and the commutator piece is performed by accommodating the winding in a hook-shaped metal member provided on the commutator piece. The hook ends of the hook-shaped metal members are electrically welded while being deformed under pressure, and the hook-shaped metal members for accommodating the intermediate portion of the winding, and both ends of the winding start end and the winding end end are accommodated. With the hook-shaped metal members, the outermost surfaces of the windings are located at substantially the same position in the longitudinal direction of the central axis, and the hook ends of the hook-shaped metal members that are deformed under pressure are deformed into substantially the same shape. A method for manufacturing a rotor of a DC motor, characterized in that:

In the above, a hook-shaped metal member to which both ends of a winding start end and a winding end end are connected is formed deeper by one winding than other hook-shaped metal members, and the winding constitutes a rotor. It is most reasonable to stack them in the longitudinal direction of the central axis, and it is preferable because the hook-shaped metal can be prevented from increasing in the radial direction of the central axis, and the winding can be easily accommodated. .

According to the rotor and commutator of the DC motor and the method for manufacturing the rotor of the present invention as described above, the hook-shaped metal member to which the intermediate portion of the winding is connected, the winding start end of the winding, Hook-shaped hardware to which both ends of the winding end are connected,
In any case, the electrodes can be electro-welded under the same pressing conditions. As a result, it is possible to reliably perform electric welding at each connection portion without fusing, fatigue, and disconnection of the winding due to excessive pressurizing pressure, and without energizing failure due to insufficient pressurizing pressure. Can be formed.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is applied to a rotor 1 having a three-pole structure will be described below with reference to the accompanying drawings.

FIG. 1 is an exploded view of a winding connection portion of a commutator 2 of a rotor 1 of the embodiment. Rotor 1
Has a structure as shown in FIG. 2 and has three salient poles 4 radially around an intermediate portion of the central axis 3 (here, the shape of the salient poles is not particularly limited. Is provided, and a commutator 2 including three commutator pieces 2a (see FIG. 3) is provided around one end of the central shaft 3. Each commutator piece 2a of the commutator 2 includes:
At the center of the salient pole 4 side, hook-shaped hardware 6a, 6b having a substantially U-shaped cross section for connecting a winding 5 wound around the salient pole 4 (see FIG. 5) are arranged along the central axis 3. It is provided in.

The hook-shaped metal members 6a and 6b are of two types as shown in FIG. 4. One hook-shaped metal member 6a having a deeply formed winding accommodating portion 7a is provided on one commutator piece 2a. And one hook-shaped metal member 6b having a shallowly formed winding accommodating portion 7b is connected to the other two commutator segments 2b.
a. Winding accommodation parts 7a, 7b
Has a width substantially equal to the wire diameter of the winding 5. The hook-shaped metal member 6a in which the winding accommodating portion 7a is formed deeply accommodates two windings 5 in a stacked manner, and a hook end 8a of a predetermined length extends above the accommodated windings 5. It is.
On the other hand, a hook-shaped metal member 6b in which the winding accommodating portion 7b is formed shallowly
The hook 5 accommodates one winding 5 and a hook end 8b having a predetermined length also extends above the accommodated winding 5. The winding accommodating portion 7a of the hook-shaped metal member 6a is deeper by one winding 5 than the winding accommodating portion 7b of the hook-shaped metal member 6b. A hook-shaped metal member 6a having a deep winding accommodating portion 7a and a hook-shaped metal member 6 having a shallow winding accommodating portion 7b.
b, the hook ends 8a, 8b are arranged at substantially the same position with the bottoms of the winding accommodating portions 7a, 7b being different from each other as indicated by the dotted lines E and C in FIG. It is like that. As a result, the outermost surface of the winding 5 when the hook-shaped metal member 6a accommodates the two windings in the direction of the central axis 3 (the vertical direction in FIG. 4) becomes the B line, and the hook-shaped metal member 6a The outermost surface of the winding 5 when the single winding 6b accommodates one winding 5 is also set to the B line.

A winding 5 wound a predetermined number of times around the pole cores 4a of the three salient poles 4 with respect to the hook-shaped metal members 6a and 6b as described above.
Are sequentially connected to form the rotor 1. FIG.
The winding of the salient pole 4 of the winding 5 around the pole core 4a and the commutator piece 2
The state of connection to a is expanded and shown. That is,
The winding start end 5a of the winding 5 is temporarily wound on a hook-shaped metal member 6a having a deeper winding accommodating portion 7a, and is wound around the pole core 4a of the first salient pole 4 (in FIG. Pole)
Next, the winding 5 is passed through the hook-shaped metal part 6b of the adjacent commutator piece 2a having the shallower winding accommodating portion 7b, and then wound around the pole core 4a of the adjacent salient pole 4 (in FIG. Similarly, after the winding 5 is passed through the hook-shaped metal member 6b in which the winding accommodating portion 7b of the adjacent commutator piece 2a is made shallow, it is wound around the pole core 4a of the adjacent salient pole 4 ( In the figure, this is the third pole), and the winding end 5b of the winding 5 is connected to the first pole.
The hook-shaped metal piece 6a of the pole commutator piece 2a is temporarily locked so as to be stacked on the temporarily locked winding start end 5a. Then, an electric current is passed between the electrode 9 and the hook-shaped hardware 6a, 6b while sequentially pressing the electrode 9 in the shape shown in the figure against each of the hook-shaped hardware 6a, 6b. The rotor 1 is completed by pressing and deforming the hook ends 8a and 8b of the hooks 6a and 6b and electrically welding the windings 5 and the hook-shaped metal members 6a and 6b.

[0015] Winding accommodating portion 7 of each hook-shaped hardware 6a, 6b
The outermost surface (the uppermost surface in the figure) of the winding 5 housed in the a and 7b in the longitudinal direction of the central axis 3 is aligned with the line B indicated by the dotted line, and the hook ends 8a extending therefrom.
8b, one kind of electrode 9 as shown in FIG.
Thus, it is possible to electrically weld the hook-shaped hardware 6a, 6b and the winding 5 under the same conditions.

FIG. 1 shows a rotor 1 completed as described above.
The hook end portions 8a and 8b of the hook-shaped metal members 6a and 6b are represented by 1 respectively.
The electrodes 9 are deformed under pressure into substantially the same shape, and are electro-welded in that state. Each of the hook-shaped metal members 6a, 6b has a hook end 8a, 8b which can accommodate the winding 5 without difficulty and is deformed under pressure at the time of electric welding in substantially the same shape. Since it is possible to prevent the winding 5 from coming out when pressed, it is possible to uniformly set the conditions of the electric welding such as the pressing pressure and the current to the hook-shaped metal members 6a and 6b on the electrode 9 side. The wire 5 and the hook-shaped metal members 6a and 6b can be reliably electrically welded, and a highly reliable connection portion can be formed. In addition, it is possible to prevent the winding 5 from being melted or fatigued due to excessive pressurizing pressure. Of course, poor connection due to insufficient pressurizing pressure can also be avoided.

FIG. 6 shows a commutator 2 in a conventional rotor.
2 is an expanded view of the shape of the hook-shaped metal member 26 provided on each commutator piece 22a of FIG. A conventionally used electrode 29 for electro welding is also shown. As is apparent from the figure, the hook-shaped metal members 26 provided on each commutator piece 22a all had the same shape. For this reason, as shown in the figure, when the electrode 29 is used for the electric welding, in the portion of the hook-shaped metal member 26 (the first pole) accommodating the two windings 25, the windings 25 come off, fusing, and fatigue. There was a possibility that this would occur. Further, in the portion of the hook-shaped metal member 26 (the second and third poles) accommodating one winding 25,
Insufficient electrical welding may cause poor connection.

[0018]

As described above, the rotor and the commutator of the DC motor according to the present invention include a hook-shaped metal winding accommodating portion to which both ends of a winding start end and a winding end are connected. Since the depth is made deeper than that of the other hook-shaped hardware, the connection between the winding and the hook-shaped hardware can be formed under the same electrical welding conditions, so that the connection reliability is high.
In the method for manufacturing a DC motor according to the present invention, the hook-shaped metal part to which both ends of the winding start end and the winding end end are connected and the other hook-shaped metal part are wound under the same electric welding condition. Since the rotor can be connected to the wire, a rotor having high connection reliability can be manufactured.

[Brief description of the drawings]

FIG. 1 is an expanded view of a connection portion between a commutator and a winding according to an embodiment of the present invention.

FIG. 2 is a front view of the rotor of the embodiment.

FIG. 3 is a plan view of the commutator of the embodiment.

FIG. 4 is a partial cross-sectional front view of a commutator piece for describing a positional relationship between two types of hook-shaped hardware provided on the commutator of the embodiment.

FIG. 5 is a development view illustrating the winding of the winding around the pole core and the connection to the hook-shaped metal according to the same embodiment.

FIG. 6 is an expanded view of a connection portion between a conventional commutator and a winding.

[Explanation of symbols]

 Reference Signs List 1 rotor 2 commutator 2a commutator piece 3 central axis 4 salient pole 4a pole core 5 winding 5a winding start end 5b winding end end 6a, 6b hook-shaped metal member 7a, 7b winding accommodation portion 8a, 8b hook end 9 Electrode 22 Commutator 22a Commutator piece 25 Winding 26 Hook-shaped hardware 29 Electrode

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[Procedure amendment]

[Submission date] March 11, 1999

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Full text

[Correction method] Change

[Correction contents]

[Document Name] Statement

Patent application title: Rotor and commutator of DC motor and method of manufacturing rotor

[Claims]

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotor and a commutator of a DC motor and a method of manufacturing the rotor, and more particularly to a method of improving reliability of a connection between a winding and a commutator. is there.

[0002]

2. Description of the Related Art Conventionally, a rotor of a DC motor is provided with a commutator including a plurality of salient poles and a plurality of commutator pieces around a central axis, and a winding is wound around a pole core of the salient pole at a predetermined number of times. Each salient pole is manufactured to have a structure in which a winding is connected to a corresponding commutator piece. The connection between the winding and the commutator piece is performed by a method in which a hook-shaped metal piece is provided on the commutator piece, the winding is accommodated in a winding accommodating portion of the hook-shaped metal piece, and the part is press-deformed and electrically welded. ing.

[0003]

In the structure of the rotor and the method of manufacturing the same as described above, the hook-shaped hardware provided on each commutator piece has the same shape and the same structure. The number of windings accommodated for connection is different between the hook-shaped metal body to which both ends of the winding start end and the winding end end are connected, and the hook-shaped metal body to which the middle part of the winding is connected, and the pressure deformation is caused. There has been a problem that the condition of the portion to be electrically welded becomes non-uniform and a highly reliable connection cannot be made.
At present, a single type of electrode is used as the electrode to be pressed for electric welding, so that the pressing pressure is strong in the hook-shaped metal part that accommodates both ends of the winding start end and winding end. The windings caused fusing, fatigue, and separation of the windings. In addition, in the hook-shaped metal part accommodating the intermediate part of the winding, welding was insufficient and electric conduction failure occurred. In order to avoid these inconveniences, both the shape of the electrode for electrodeposition and the pressure are adjusted to achieve matching. However, in reality, satisfactory results have not been obtained.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to provide a rotor of a DC motor, a commutator, and a method of manufacturing the rotor, in which the connection between a winding and a commutator piece is highly reliable. The purpose is.

[0005]

SUMMARY OF THE INVENTION The present invention has been made based on the above-mentioned object, and has a configuration in which the shape of a hook-shaped metal member provided on a commutator piece is changed in accordance with a portion of a winding to be connected. is there.

More specifically, the present invention of claim 1 will be described with reference to the reference numerals used in the accompanying drawings corresponding to the embodiments of the present invention. Is provided, and the winding wound around the pole core of the salient pole is provided in each of the commutator pieces in a winding accommodating portion of a hook-shaped metal member having a substantially U-shaped cross section in advance. A rotor of a DC motor in which a hook end extends above the winding in the housed state and the width of the winding accommodating portion is formed in advance so as to abut the winding. It is preferable that, while the winding is accommodated in a winding accommodating portion of a hook-shaped metal and the hook-shaped metal is pressed by an electrode, an electric current flows between the electrode and the hook-shaped metal, and the hook-shaped metal is formed. The winding of the winding 5 is started in the rotor of the DC motor for welding the winding to the winding. The winding accommodating portion 7a of the hook-shaped metal member 6a to which both ends of the end 5a and the winding end end 5b are connected is smaller than the winding accommodating portion 7b of the hook-shaped metal member 6b connecting the intermediate portion of the winding 5. The winding 5
The outermost end 5b of the winding end 5b of the winding 5 of the hook-shaped metal member 6a that houses the winding start end 5a and the winding end 5b of the winding 5 in a state where the windings are accommodated in the winding accommodation portions 7a and 7b, respectively. The side surface and the outermost surface of the intermediate portion of the winding 5 of the hook-shaped metal member 6b that accommodates the intermediate portion of the winding 5 are located at substantially the same position in the longitudinal direction of the central axis 3, and the electrodes 9 Each of the hook-shaped metal members 6a, 6b is pressed toward the central axis 3 while being electrically welded and deformed under pressure. At the same time, the hook-shaped metal members 6a, 6b accommodate the winding start end 5a and the winding end end 5b. In the winding accommodating portion 7a of the metal piece 6a, the winding start end 5a of the winding 5 and the winding end end 5b stacked thereon are equally pressed, and the hook end 8a is pressed.
Is bent so as to be in contact with the outermost surface of the winding end 5b of the winding 5, and in the winding receiving portion 7b of the hook-shaped metal member 6b in which the intermediate portion of the winding 5 is stored. 5 and the hook end 8b
Is bent so as to contact the outermost surface of the intermediate portion of the winding 5.

The present invention according to claim 2 comprises a plurality of commutator pieces attached around a central axis of a rotor of a DC motor, and each of the commutator pieces is provided around the central axis. A hook-shaped metal member having a substantially U-shaped cross section is provided in advance to connect the winding wound around the pole core of the salient pole to be formed, and a hook-shaped metal member between the commutator piece and the hook-shaped metal member is provided. A hook end extends above the winding in a state in which the winding is accommodated in the winding accommodating portion, and the width of the winding accommodating portion is previously formed to a width such that the winding abuts. While pressing the hook-shaped metal with an electrode,
In a commutator of a DC motor for applying a current between the hook-shaped metal member and the winding to electrically weld the hook-shaped metal member and the winding, a winding start end 5a of the winding 5 and The winding accommodating portion 7a of the hook-shaped metal member 6a to which both ends of the winding end 5b are connected is one coil deeper than the winding accommodating portion 7b of the hook-shaped metal member 6b connecting the intermediate portion of the winding 5. In a state where the winding 5 is housed in each of the winding housing portions 7a and 7b, the winding of the hook-shaped metal member 6a housing the winding start end 5a and the winding end end 5b of the winding 5 is formed. 5 is substantially the same as the outermost surface of the intermediate portion of the winding 5 of the hook-shaped metal member 6b containing the intermediate portion of the winding 5 in the longitudinal direction of the center shaft 3. While pressing each of the hook-shaped hardware 6a, 6b toward the central axis 3 by the electrode 9, At the same time as being deformed by welding while being welded, the winding start end of the winding 5 is formed in the winding housing portion 7a of the hook-shaped metal member 6a in which the winding start end 5a and the winding end end 5b of the winding 5 are housed. 5a and the winding end 5b stacked thereon are equally pressed,
The hook end 8a is bent so as to be in contact with the outermost surface of the winding end 5b of the winding 5, and the winding receiving portion 7b of the hook-shaped metal member 6b in which the intermediate portion of the winding 5 is stored.
In, while the intermediate portion of the winding 5 is pressurized,
A commutator for a DC motor, wherein the hook end 8b is bent so as to be in contact with an outermost surface of an intermediate portion of the winding 5.

According to a third aspect of the present invention, a winding is wound around the pole cores of a plurality of salient poles provided around a central axis, and a winding is provided around the central axis for each salient pole. When housed in the winding accommodating portion of the hook-shaped metal piece formed in advance in a substantially U-shaped cross-section provided on each of the commutator pieces corresponding to the commutator, the hook ends extend above the winding. In addition, the width of the winding accommodating portion is formed in advance so as to be in contact with the winding, and while pressing the hook-shaped metal with an electrode, a current is applied between the electrode and the hook-shaped metal. In the method for manufacturing a rotor of a DC motor, in which the hook-shaped metal piece and the winding are electrically welded to connect the winding and the commutator piece, the winding start end 5a of the winding 5 And the winding accommodating portion 7a of the hook-shaped metal member 6a to which both ends of the winding end 5b are connected, The intermediate portion of the winding 5 is formed so as to be deeper by one winding than the winding accommodating portion 7b of the hook-shaped metal member 6b to be connected, and the winding 5 is accommodated in each of the winding accommodating portions 7a and 7b. In this state, the winding 5 of the hook-shaped metal member 6a accommodating the winding start end 5a and the winding end end 5b of the winding 5
The outermost surface of the winding end 5b and the outermost surface of the intermediate portion of the winding 5 of the hook-shaped metal member 6b that accommodates the intermediate portion of the winding 5 are substantially at the same position in the longitudinal direction of the central axis 3. When the electrode 9 presses and deforms the hook-shaped metal members 6a and 6b toward the central axis 3 while pressing the metal members 6a and 6b, the lower surface 9d of the electrode 9 is fixed to the hook-shaped metal member 6a.
a at the same position as the lower surface 50 of the hook-shaped metal member 6a in which the winding start end 5a and the winding end end 5b of the winding 5 are housed. The second pressing surface 9b is located at a position where the hook end 8a of the hook-shaped metal member 6a can be bent toward the central axis 3, and the first pressing surface 9a of the electrode 9 causes the winding 5 to move. While equally pressing the winding start end 5a and the winding end end 5b stacked thereon,
The hook end 8a is bent by the second pressing surface 9b of the electrode 9, and the bent hook end 8a is the end of the winding end 5b of the winding 5 pressed by the first pressing surface 9a of the electrode 9. The winding accommodating portion 7b of the hook-shaped metal member 6b in which the intermediate portion of the winding 5 is accommodated so as to be in contact with the outer side surface
In the above, the second pressing surface 9b of the electrode 9 is located at a position where the hook end 8b of the hook-shaped metal member 6b can be bent toward the central axis 3, and the first pressing surface 9b of the electrode 9 is pressed. The intermediate portion of the winding 5 is pressed by the surface 9a, and the hook end 8b is bent by the second pressing surface 9b of the electrode 9, and the bent hook end 8 is bent.
A method for manufacturing a rotor of a DC motor, wherein b is in contact with an outermost surface of an intermediate portion of a winding 5 pressed by a first pressing surface 9a of the electrode 9.

In the above, a hook-shaped metal member to which both ends of a winding start end and a winding end end are connected is formed deeper by one winding than other hook-shaped metal members, and the winding constitutes a rotor. It is most reasonable to stack them in the longitudinal direction of the central axis, and it is preferable because the hook-shaped metal can be prevented from increasing in the radial direction of the central axis, and the winding can be easily accommodated. .

According to the rotor and commutator of the DC motor and the method for manufacturing the rotor of the present invention as described above, the hook-shaped metal member to which the intermediate portion of the winding is connected, the winding start end of the winding, Hook-shaped hardware to which both ends of the winding end are connected,
In any case, the electrodes can be electro-welded under the same pressing conditions. As a result, it is possible to reliably perform electric welding at each connection portion without fusing, fatigue, and disconnection of the winding due to excessive pressurizing pressure, and without energizing failure due to insufficient pressurizing pressure. Can be formed.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is applied to a rotor 1 having a three-pole structure will be described below with reference to the accompanying drawings.

FIG. 1 is an exploded view of a winding connection portion of a commutator 2 of a rotor 1 of the embodiment. Rotor 1
Has a structure as shown in FIG. 2 and has three salient poles 4 radially around an intermediate portion of the central axis 3 (here, the shape of the salient poles is not particularly limited. Is provided, and a commutator 2 including three commutator pieces 2a (see FIG. 3) is provided around one end of the central shaft 3. Each commutator piece 2a of the commutator 2 includes:
In order to connect the winding 5 wound around the salient pole 4 to the center of the salient pole 4 (see FIG. 5), hook-shaped metal members 6a and 6b having a substantially U-shaped cross section are attached to the center shaft 3. It is provided so that it may follow.

The hook-shaped metal members 6a and 6b are of two types as shown in FIG. 4. One hook-shaped metal member 6a having a deeply formed winding accommodating portion 7a is provided on one commutator piece 2a. And one hook-shaped metal member 6b having a shallowly formed winding accommodating portion 7b is connected to the other two commutator segments 2b.
a. The widths of the winding accommodating portions 7a and 7b are set to be approximately equal to the wire diameter of the winding 5 in advance. Hook-shaped metal member 6a in which winding accommodation portion 7a is formed deep
The two windings 5 are stacked and accommodated, and a hook end 8a having a predetermined length extends above the accommodated windings 5. On the other hand, the hook-shaped metal member 6b in which the winding accommodating portion 7b is formed shallowly accommodates one winding 5, and the hook end 8b having the same length also extends above the accommodated winding 5. It is. The winding accommodating portion 7a of the hook-shaped metal member 6a is deeper by one winding 5 than the winding accommodating portion 7b of the hook-shaped metal member 6b. The hook-shaped metal member 6a having the winding accommodating portion 7a formed deeply and the hook-shaped metal member 6b having the coil accommodating portion 7b formed shallowly have the bottom portions of the winding accommodating portions 7a and 7b indicated by dotted lines in FIG. And the hook ends 8a and 8b are arranged at substantially the same position as shown in FIG. As a result, the hook-shaped hardware 6a
When the two windings are accommodated, the outermost surface of the winding 5 in the direction of the central axis 3 (up and down direction in FIG. 4) becomes the B line, and the hook-shaped metal member 6b has one winding. When the wire 5 is accommodated, the outermost surface of the winding 5 is also set to the B line.

A winding 5 wound a predetermined number of times around the pole cores 4a of the three salient poles 4 with respect to the hook-shaped metal members 6a and 6b as described above.
Are sequentially connected to form the rotor 1. FIG.
The winding of the salient pole 4 of the winding 5 around the pole core 4a and the commutator piece 2
The state of connection to a is expanded and shown. That is,
The winding start end 5a of the winding 5 is temporarily wound on a hook-shaped metal member 6a having a deeper winding accommodating portion 7a, and is wound around the pole core 4a of the first salient pole 4 (in FIG. Pole)
Next, the winding 5 is passed through the hook-shaped metal part 6b of the adjacent commutator piece 2a having the shallower winding accommodating portion 7b, and then wound around the pole core 4a of the adjacent salient pole 4 (in FIG. Similarly, after the winding 5 is passed through the hook-shaped metal member 6b in which the winding accommodating portion 7b of the adjacent commutator piece 2a is made shallow, it is wound around the pole core 4a of the adjacent salient pole 4 ( In the figure, this is the third pole), and the winding end 5b of the winding 5 is connected to the first pole.
The hook-shaped metal piece 6a of the pole commutator piece 2a is temporarily locked so as to be stacked on the temporarily locked winding start end 5a. Then, the lower surface 9d of the electrode 9 having the illustrated shape is sequentially positioned at the same position as the lower surface 50 of the hook-shaped metal member 6a for each of the hook-shaped metal members 6a and 6b. An electric current flows between the hook-shaped metal members 6a and 6b, and the hook ends 8a and 8 of the respective hook-shaped metal members 6a and 6b.
b is deformed under pressure, and the winding 5 and the hook-shaped metal members 6a, 6b
The rotor 1 is completed by electro welding. At this time, the lower surface 9d of the electrode 9 is connected to the lower surface 5 of the hook-shaped metal member 6a.
0 and the electrode 9 presses the hook-shaped metal member 6a with the electrode 9 so that the winding start end 5a and the winding end end 5b of the winding 5 are housed.
In the winding accommodating portion 7a, the second pressing surface 9b of the electrode 9 is arranged so that the hook end 8a of the hook-shaped metal member 6a is
, And the first pressing surface 9a of the electrode 9 makes the winding start end 5a of the winding 5 and the winding end end 5b stacked thereon uniform. While pressing, the hook end 8a is bent by the second pressing surface 9b of the electrode 9, and the bent hook end 8a is connected to the first pressing surface 9a of the electrode 9.
This makes contact with the outermost surface of the winding end end 5b of the winding 5 which is pressurized. Similarly, in the winding accommodating portion 7b of the hook-shaped metal member 6b in which the intermediate portion of the winding 5 is accommodated, the second pressing surface 9b of the electrode 9 has the hook end 8b of the hook-shaped metal member 6b as the center axis. 3, and the intermediate portion of the winding 5 is pressed by the first pressing surface 9 a of the electrode 9 and hooked by the second pressing surface 9 b of the electrode 9. The end 8b is bent, and the bent hook end 8b is bent.
Is pressed by the first pressing surface 9 a of the electrode 9.
To be in contact with the outermost surface of the intermediate portion.

The outermost surface (in the longitudinal direction) of the central axis 3 of the winding end 5b of the winding start end 5a and the winding end 5b of the winding 5 housed in the winding housing 7a of the hook-shaped metal member 6a. Each of the outermost side surfaces in the longitudinal direction of the central axis 3 of the intermediate portion of the winding 5 housed in the winding housing portion 7b of the hook-shaped metal member 6b is indicated by a dotted line B. Since the hook ends 8a and 8b extending from the lines are also aligned, the hook-shaped metal members 6a and 6b and the winding 5 are electrically welded under the same conditions using one kind of electrode 9 as shown in the figure. It is possible to

FIG. 1 shows a rotor 1 completed as described above.
The hook end portions 8a and 8b of the hook-shaped metal members 6a and 6b are represented by 1 respectively.
The electrodes 9 are deformed under pressure into substantially the same shape, and are electro-welded in that state. Each of the hook-shaped metal members 6a, 6b has a hook end 8a, 8b, which accommodates the winding 5 without difficulty and is deformed under pressure during electric welding, in substantially the same shape. In other words, in the winding receiving portion 7a of the hook-shaped metal member 6a in which the winding start end 5a and the winding end end 5b of the winding 5 are stored, the winding start end 5a of the winding 5 and the winding start end 5a are stacked thereon. And the hook end 8a is bent so that the hook end 8a is in contact with the outermost surface of the winding end 5b of the winding 5, and the intermediate portion of the winding 5 is accommodated. Hook-shaped hardware 6b
In the winding accommodating portion 7b, the intermediate portion of the winding 5 is pressurized and the hook end 8b is bent so as to contact the outermost surface of the intermediate portion of the winding 5. This allows
It is possible to prevent the winding 5 from coming off when the electrode 9 is pressurized, and to uniformly set the conditions of the electric welding such as the pressurizing pressure and the current to the hook-shaped metal members 6a and 6b on the electrode 9 side. Therefore, the wire 5 and the hook-shaped metal members 6a and 6b can be reliably electrically welded, and a highly reliable connection portion can be formed. In addition, it is possible to prevent the winding 5 from being melted or fatigued due to excessive pressurizing pressure. Of course, poor connection due to insufficient pressurizing pressure can also be avoided.

That is, each of the rotor 1 and the commutator 2 of the DC motor of the present invention has a hook-shaped metal member 6a to which both ends of a winding start end 5a and a winding end end 5b of the winding 5 are connected. The winding accommodating portion 7a is formed to be deeper by one winding than the winding accommodating portion 7b of the hook-shaped metal member 6b connecting the intermediate portion of the winding 5, and the winding accommodating portion 7a , 7b, the outermost surface of the winding end 5b of the hook 5 having the winding start end 5a and the winding end 5b of the winding 5 housed therein, The outermost surface of the intermediate portion of the winding 5 of the hook-shaped metal member 6b accommodating the intermediate portion of the hook 5 is located at substantially the same position in the longitudinal direction of the central axis 3, and the hook-shaped metal members 6a, 6b Each of the central axis 3
At the same time, the wire 5 is deformed under pressure while being electrically welded while being pressed toward the winding end 5 a and the winding end 5 a of the winding 5.
In the winding accommodating portion 7a of the hook-shaped metal member 6a accommodating the winding start end 5a of the winding 5 and the winding end end 5b stacked thereon, pressure is evenly applied. The hook end 8a is a winding end 5 of the winding 5.
b is bent so as to be in contact with the outermost surface of the winding 5b, and the intermediate portion of the winding 5 is pressed in the winding receiving portion 7b of the hook-shaped metal member 6b in which the intermediate portion of the winding 5 is stored. At the same time, the hook end 8b is bent so as to be in contact with the outermost surface of the intermediate portion of the winding 5.

FIG. 6 shows a commutator 2 in a conventional rotor.
2 is an expanded view of the shape of the hook-shaped metal member 26 provided on each commutator piece 22a of FIG. A conventionally used electrode 29 for electro welding is also shown. As is apparent from the figure, the hook-shaped metal members 26 provided on each commutator piece 22a all had the same shape. For this reason, as shown in the figure, when the electrode 29 is used for the electric welding, in the portion of the hook-shaped metal member 26 (the first pole) accommodating the two windings 25, the windings 25 come off, fusing, and fatigue. There was a possibility that this would occur. Further, in the portion of the hook-shaped metal member 26 (the second and third poles) accommodating one winding 25,
Insufficient electrical welding may cause poor connection.

[0019]

As described above, the rotor and the commutator of the DC motor according to the present invention include a hook-shaped metal winding accommodating portion to which both ends of a winding start end and a winding end are connected. Since the winding is deeper by one winding than the winding receiving portion of the other hook-shaped hardware, the connection between the winding and the hook-shaped metal can be made to have the same electrical welding conditions to form a highly reliable connection. it can. Further, the method of manufacturing a DC motor according to the present invention includes a hook-shaped metal part to which both ends of a winding start end and a winding end are connected, and a hook-shaped metal part to which an intermediate part of the winding is connected. Since the connection with the winding can be made under the same welding condition, a rotor with high connection reliability can be manufactured.

[Brief description of the drawings]

FIG. 1 is an expanded view of a connection portion between a commutator and a winding according to an embodiment of the present invention.

FIG. 2 is a front view of the rotor of the embodiment.

FIG. 3 is a plan view of the commutator of the embodiment.

FIG. 4 is a partial cross-sectional front view of a commutator piece for describing a positional relationship between two types of hook-shaped hardware provided on the commutator of the embodiment.

FIG. 5 is a development view illustrating the winding of the winding around the pole core and the connection to the hook-shaped metal according to the same embodiment.

FIG. 6 is an expanded view of a connection portion between a conventional commutator and a winding.

[Description of Signs] 1 rotor 2 commutator 2a commutator piece 3 center axis 4 salient pole 4a pole core 5 winding 5a winding start end 5b winding end end 6a, 6b hook-shaped hardware 7a, 7b winding housing 8a, 8b Hook end 9 Electrode 9a First pressing surface 9b Second pressing surface 9c Upper surface 9d Lower surface 22 Commutator 22a Commutator piece 25 Winding 26 Hook-shaped hardware 29 Electrode 50 Lower surface

[Procedure amendment 2]

[Document name to be amended] Drawing

[Correction target item name] Fig. 1

[Correction method] Change

[Correction contents]

FIG.

[Procedure amendment 3]

[Document name to be amended] Drawing

[Correction target item name] Fig. 5

[Correction method] Change

[Correction contents]

FIG. 5

Claims (8)

[Claims] 1. A commutator comprising a plurality of salient poles and a plurality of commutator pieces is provided around a central axis, and a winding wound around a pole core of the salient poles is connected to the commutator piece via a hook-shaped metal member. In the rotor of the DC motor, the winding housing portion 7a of the hook-shaped metal member 6a to which both ends of the winding start end 5a and the winding end end 5b of the winding 5 are connected is connected to another hook-shaped metal member 6b. The hook end portions 8a of all the hook-shaped metal members 6a, 6b are formed deeper than the winding accommodating portions 7b.
A rotor for a direct-current motor, characterized in that the rotor 8b is deformed under pressure into substantially the same shape, and the connection between the winding 5 and the hook-shaped hardware 6a, 6b is electrically welded. 2. The hook-shaped metal member 6a to which both ends of the winding start end 5a and the winding end end 5b of the winding 5 are connected is such that the winding accommodating portion 7a is one coil deeper than the other hook-shaped metal members 6b. The winding start end 5a and the winding end end 5b are
The rotor of the DC motor according to claim 1, wherein the rotor is stacked in a longitudinal direction of the DC motor. 3. A commutator comprising a plurality of commutator pieces mounted around a central axis of a rotor of a DC motor, wherein the commutator is wound around a pole core 4a of a salient pole 4 provided around the central axis 3. Hook-shaped hardware 6a, 6 for connecting winding 5
b is provided for each commutator piece 2a, and a winding accommodating portion 7a of a hook-shaped metal member 6a for connecting both ends of a winding start end 5a and a winding end end 5b of the winding 5 is provided. The outermost surface of the winding 5 that is formed deeper than the winding accommodating portion 7b of the hook-shaped metal member 6b for connecting the intermediate portion and that is accommodated in each of the winding accommodating portions 7a and 7b in the longitudinal direction of the central axis 3 A commutator for a DC motor, wherein the commutator is arranged at substantially the same position. 4. The hook-shaped metal members 6a, 6b are formed in a substantially U-shaped cross section, and the width of the winding accommodating portions 7a, 7b is
The commutator of the DC motor according to claim 3, wherein the commutator has a diameter substantially equal to that of the commutator. 5. A commutator for a DC motor according to claim 3, wherein the hook-shaped metal members have a hook end for a pressurized deformation, the hook ends extending at a predetermined length. 6. A hook-shaped metal member 6a for connecting both ends of a winding start end 5a and a winding end end 5b of the winding 5 is such that the winding accommodating portion 7a is one winding larger than the other hook-shaped metal members 6b. The commutator of a DC motor according to any one of claims 3 to 5, wherein the commutator is formed deep. 7. A commutator corresponding to a commutator provided around a central axis by winding a winding around a pole core of a plurality of salient poles provided around a central axis. In the method for manufacturing a rotor of a DC motor connected to a piece, the connection between the winding 5 and the commutator piece 2a is stored in the hook-shaped metal members 6a and 6b provided on the commutator piece 2a. The hook ends 6a, 6b of the hook-shaped metal members 6a, 6b are deformed under pressure so as to be electrically welded, and a hook-shaped metal member 6b for accommodating an intermediate portion of the winding 5;
And a hook-shaped metal member 6a for accommodating both ends of the winding start end 5a and the winding end end 5b, so that the outermost surface of the winding 5 is substantially at the same position in the longitudinal direction of the central axis. A method for manufacturing a rotor of a DC motor, wherein the hook ends 8a and 8b of the DC motors 6a and 6b that are deformed under pressure are deformed into substantially the same shape. 8. The manufacturing of a rotor for a DC motor according to claim 7, wherein the winding start end 5a and the winding end end 5b of the winding 5 are stacked on the hook-shaped metal member 6a in the longitudinal direction of the center shaft 3. Method.