JPS58190255A - Manufacture of armature - Google Patents

Abstract

PURPOSE:To effectively connect a metal plating layer formed on the surface of a commutator segment to the leads of an armature coil by connecting the metal plating layer to the leads of the armature coil by a supersonic vibration welding machine. CONSTITUTION:The leads 3a of two adjacent armature coils 3 are superposed, and pressed onto a tin plating layer 5 on the end of a commutator segment 4a at the armature coil 3 side from a direction of an arrow P by the tip 10e of a supersonic vibration welding machine 10. The tip 10e is vibrated in an X direction by the vibration of a magnetostrictive vibrator 10a, the two leads 3a are solid-solution bonded by frictional energy, the layer 5 is simultaneously fusion- bonded and mixed to the leads 3a adjacent to the layer 5 and the segment 4a, and the two leads 3a are effectively secured to the segment 4a.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an armature, and more particularly to a method of connecting an outlet of an armature coil made of aluminum wire to a commutator segment made of copper.

Conventionally, when aluminum wire is used for the armature coil, the connection between the lead portion of the armature coil and the copper commutator segment is a loop portion, so the following two methods have been proposed. i.e. CI).

A method of cladding the end of the armature coil side on the surface of a steel commutator segment with an aluminum layer, and connecting the lead portion of the armature coil to the aluminum layer of the commutator segment using aluminum solder; In the past, there was a method in which a connection terminal for caulking was provided on a part of the armature coil side of a copper luxury element segment, and the protruding part of the armature coil was caulked to this connection terminal.

However, in the first conventional method, an aluminum layer is clamped to one end on the surface of a copper commutator segment, which makes the commutator segment expensive. In addition, aluminum solder generally has very poor soldering properties and lacks reliability, and soldering requires a high degree of skill, which often results in poor workability. On the other hand, the conventional second
In this method, since it is necessary to provide a connection terminal for caulking the commutator segment with the armature coil opening, there is a drawback that the number of manufacturing steps is increased and the manufacturing cost is high.

This invention was made in view of the above-mentioned drawbacks, and when connecting the lead part of an armature coil using aluminum wire to a copper commutator segment, a metal wire that can be melted and mixed with aluminum and copper is used. Reliability is improved by forming a plating layer on the surface of the commutator segment and connecting the lead portion of the armature coil to the commutator segment via the plating layer using an ultrasonic vibration welding device. An object of the present invention is to provide a method for manufacturing an armature that can reduce the manufacturing cost.

Hereinafter, Fig. 1 and Fig. 111 (A) of the method according to an embodiment of the present invention show the scattered portion of the commutator at the stage of connecting the outlet portion of the armature coil to the commutator segment in the method of this embodiment. Only the side view shown in the cross section of the pipe, and the side view shown in Figure 1 (Bl tl sectional view taken along the line 1B-FB in Figure 1 (A). In addition, Figure 1 FB) shows the armature core and armature coil. is omitted, and only the end face of the armature coil outlet is shown.

In the figure, (1) is the armature rotation shaft, (2) is the armature core fitted onto the armature rotation shaft (1), and (3) is made of aluminum wire, which is attached to the outer peripheral surface of the 11 armature core 2). (3a) A plurality of armature coils are arranged in a corrugated manner in slots (not shown) provided between both end faces parallel to the axial direction at predetermined intervals in the circumferential direction. are openings provided in each armature coil (3). (4)
is a cylindrical commutator that supplies current to the armature coil (3) through its outlet i[3a] to excite the armature core (2) and rotate it. of-
Commutator segments (41
L) and a bushing (4) fitted onto the armature rotating shaft (1).
b) and a resin (4C) molded to insulate and fix each commutator segment (shaft) and at the same time to be fixed to the bush (4b).
i Each commutator segment) (4a) is a tin plating layer formed on the surface of each commutator segment. The ring is an ultrasonic vibration welding device, (loa) is a magnetostrictive vibrator that has an opening shape and vibrates magnetostrictively at an ultrasonic frequency in the direction of the arrow X shown in the figure, and (10b) is a magnetostrictive vibrator (10a) that is wound around the magnetostrictive vibrator (10a). The coil (loc) is the coil (10
(lod) is connected to both terminals of the coil (1ob) and supplies a current at an ultrasonic frequency to energize the magnetostrictive vibrator (10a);
) is fixed to the end face in the direction of arrow X, and has a cross-sectional shape that becomes smaller as it moves away from the magnetostrictive oscillator (1 oa), and amplifies the amplitude of the magnetostrictive vibration of the magnetostrictive oscillator (1 oa); (10e) is a tip that is fixed to the other end face of the horn (lod) and performs ultrasonic vibration welding.

Next, in the method of this embodiment, the commutator segment (4a) of the commutator (4) is attached to the outlet portion (
The step of connecting 3a) will be explained.

At this stage, as shown in FIG. Armature coil (3) Tin plating layer on the end of 9111 (5) Ultrasonic vibration contacting device U tip (10e)
Press from the direction of arrow P using . Next, the power supply (
10o) to the coil (10b) to energize the magnetostrictive vibrator (10a) to cause magnetostrictive vibration,
The amplitude of the magnetostrictive vibration is amplified by the bone (XOd) to vibrate the chip (10e) in the X direction. The vibration of this tip (1oe) and the force of pressing the two openings (3&) of the balance (10e) against the Tatami Ryuko segment (4a) through the tin plating layer (5) generate two At the same time as the two lead parts (3a) are welded in the same phase, the tin plating layer (5) is melted and mixed with the adjacent lead part (3a) and the commutator segment (4a). The openings (3a) are securely fixed to the commutator segments (4a).

After performing such operations on each commutator segment (4a), a side view corresponding to FIG. 1(A) is shown in FIG. 2(A), and a side view corresponding to FIG. The second corresponding to figure (B)
Figure (As shown in the cross-sectional view taken along the line ■B-[IB of Al,
The parts other than the fixed parts between a) and commutator segment) (4a) are cut off from the surface of each commutator segment) (4a) by lathe machining, and these commutator segment) (
When the surface of 4a) is exposed to provide a sliding contact surface with an electric brush (not shown), the operation of the method of this embodiment is completed.

In this embodiment, the armature coil (3) has an opening 1 (3a).
) through the tin-plated layer (5) to the commutator segment (4).
a) can be reliably fixed by ultrasonic vibration welding equipment WOO, so the reliability of soldering can be much improved compared to the case of the conventional first method using aluminum solder, which has poor properties. can. commutator segment)
The lead part (3a) of the armature coil (3) can be connected to the commutator segment (4a) by simply forming the tin plating layer (5) on the surface of the commutator segment (4a). Compared to the conventional #11 method in which the aluminum layer is clamped to one end of the aluminum layer, and the conventional second method in which a special crimping terminal is used, the manufacturing man-hours are reduced. The manufacturing cost can be reduced.In this example, the tin plating layer (5) is used, but this need not necessarily be limited to the tin plating layer! Nickel, which can be melted and mixed with aluminum and copper, rather than
A plating layer of metal such as solder may also be used.

As explained above, in the method for manufacturing an armature of the present invention, when connecting the lead part of the armature coil using an aluminum spool to a copper commutator segment, a metal that can be melted and mixed with aluminum and copper is used. A Metsu P layer of I! is formed on the surface of the commutator segment, and the I! layer is applied to the commutator segment via the plating layer. Since the armature coil outlet is connected using an ultrasonic vibration welding device, it is possible to securely fix the commutator segment and the armature coil outlet, improving reliability. can. Furthermore, since it is only necessary to form the metal plating layer on the surface of the commutator segment, the number of manufacturing steps can be reduced and the manufacturing cost can be reduced.

[Brief explanation of the drawing]

FIG. 1 (A) Fi is a side view showing only the commutator in cross section, showing the main part of the state at the stage of connecting the lead portion of the armature coil to the commutator segment in the method of one embodiment of the present invention;
Figure (B) is a sectional view taken along line 1B-iB in Figure 1 (A), and Figure 2 (A) is a step of forming a sliding surface of the commutator segment with the electric brush in the method of the above embodiment. FIG. 2(B) is a side view showing the main part of the state in a cross section of only the commutator, and FIG. 2(B) is a sectional view at IIB-111B#l in FIG. 2(A). In the figure, (2) is the armature core, (3) is the armature coil, (3a) is the 9-output part of the armature coil, (4) is the id commutator, (4a) is the commutator segment, and (5) is the Tin plating layer (metal plating Jg4 that can be melted and mixed with aluminum and copper), Q ($ is an ultrasonic vibration welding device. In addition, the same reference numerals in the figure indicate the same or similar parts. Agent Ge Shuxin - (1 other person) 11121, 10c Figure 2

Claims (1)

[Claims] (1) The opening of the armature coil made of aluminum wire and wound around the armature core is provided at a portion of the outer peripheral surface of the commutator made of copper that corresponds to the opening of the armature coil. A metal intermediate layer of a metal that can be melted and mixed with aluminum and copper is formed on the surface of the commutator segment to connect to the commutator segment, and the armature coil of the commutator segment is connected to the commutator segment through the plating layer. The lead part of the armature coil is brought into contact with the side end and fixed using an ultrasonic vibration welding device, and then the part of the plating layer other than the part where the lead part of the armature coil and the commutator segment are fixed is A portion is removed from the surface of the commutator segment to expose the surface of the commutator segment, and the exposed surface of the Ii flow segment is used as a sliding contact surface with an electric brush. A method of manufacturing an armature.