JPS5846945B2 - Manufacturing method of cup-shaped armature - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a cup-shaped ironless armature.

To manufacture a conventional cup-shaped coreless armature, the armature winding is first wound with a winding machine to form a cup shape, and this winding is inserted into a shaping mold and shaped into a predetermined shape.

Thereafter, the lead wire of the winding to the commutator is connected to the riser of the commutator to which the shaft is attached, and the armature winding assembly is completed.

Next, the winding assembly is placed in a casting mold, and a resin solution such as epoxy is injected under reduced pressure and cured by heating to obtain a coreless armature.

However, since the solution viscosity is very low, this method requires a very long time (more than 1 hour) for heating and curing, requires many molds, a heating furnace, and also requires resin injection. Otherwise, it is not suitable for mass production because it takes a lot of work time to remove particles, etc. Also, because it is a vacuum casting process, there are areas where the resin is not injected, such as air bubbles, which weakens the strength of the armature and causes quality problems. Ta.

As a means to improve the conventional method, the armature winding assembly is inserted into a mold, and semi-cured resin is heated from the outside by a gate provided at the cup opening or bottom outer periphery of the cup-shaped armature. A method of pressurized injection has been proposed.

However, with this method, many molds can be made into small assemblies and injected all at once from one pot, and the curing time is only a few minutes, so mass production is much improved compared to the above-mentioned method, but the resin If the wire diameter of the armature winding is small, it will not be able to withstand the injection pressure of the resin, causing the winding to become deformed, or lead wires to the commutator to break, or the winding to There were problems such as short circuits because they were brought into close contact.

The present invention solves all the problems of the above conventional methods, and will be explained below with reference to the accompanying drawings.

In FIG. 1, reference numeral 1 denotes an armature winding having a predetermined number of coil bundles made by winding a predetermined number of self-fused wires using a winding jig, and 2 a lead-out wire connected to a commutator.

Figure 2 shows the manufacturing equipment, in which 3 is a cylindrical convex mold A16 having a shaft insertion hole 4 in the center and a protrusion 5 on the upper part of the outer periphery, which holds the mold A3 vertically movably. B, 7 is a coil spring 9 that biases the mold A3 in order to make the protrusion 5 of the mold A3 protrude from the upper end surface 8 of the mold B6;
C110 is a concave upper mold that shapes the outer periphery of the winding into a predetermined shape.
is a mold D112 which has a commutator insertion hole 11 in the center and is installed loosely in the central recess of the mold C9.
A coil spring 13 is installed between the shaft 1 and the mold E114, and a coil spring 13 is slidably installed on the outer periphery of the mold B6.
5 is a commutator attached, 16 is a ring-shaped thermosetting resin plate, and 1γ is a protective cap provided to prevent resin from adhering to the undercut portion and outer periphery of the commutator 14.

Next, the manufacturing process will be explained.

First, mold A3 and mold B6 are heated and maintained at a predetermined temperature.

Next, the thermosetting resin plate 16 is placed on the upper end surface of the mold B6, and the armature winding 1 connected to the commutator 14 is inserted from above, centering on the shaft insertion hole 4 of the mold A3. .

Next, the mold C9 is inserted little by little from above the winding 1.

By inserting the mold C9, the armature winding 1 is rectified into a predetermined shape, and the commutator 14 is pushed by the mold D10, so that the molded end 18 of the commutator 14 is brought into close contact with the upper surface of the mold A3. Ru.

Next, before the mold C9 is inserted to a predetermined position, the mold E
13 is pushed up from below to shape the coil end 19, and finally, the mold C9 is tightened, and the resin plate 16 is melted and filled into the space formed by the molds A to E.

After holding this state for several minutes and removing the molds C and D after the resin has hardened, the mold A3 is lifted by the repulsive force of the coil spring 7, and as a result, as shown in FIG. The completed armature is also lifted slightly above the mold.

Thereafter, the completed armature is taken out from the molds A and B, and the process is completed.

In the above embodiment, the shaft was integrally fixed to the commutator and molded with resin, but it is of course possible to attach the shaft 4 later as a jig. It goes without saying that 14 and the collar may be integrally molded and fixed with the resin.

Furthermore, it goes without saying that a permanent magnet plate for detecting the number of rotations of the armature or a resistor for protecting the commutator segments may be integrally formed with the armature winding.

As is clear from the above embodiments, the present invention provides the following effects.

1. Heat fluidization of the resin and shaping of the winding wire can be done in the same mold, and the resin fixation of the winding wire can be done at the same time, making it very efficient.

Furthermore, equipment and mold costs are also significantly lower.

2. In the conventional case, resin remained in runners, pots, etc., and the resin used in the product was 20 to 30%, but in the case of the present invention, the amount of unnecessary resin is zero.

This reduces the cost of the resin. 3 The resin is injected at a pressure slightly higher than normal pressure, and the windings are fixed with the resin in a short time, making it easy to work and preventing shorts and shorts in the armature windings.
No heat generation such as disconnection or bending occurs.

4. Since the conventional 2-3 steps are completed in 1 step, loss is greatly reduced and quality is stable.

5. Since it is possible to use A-stage (raw resin) as the resin material, it has good compatibility with the self-bonding coating or insulation coating applied to the electric wire, and since the resin and the electric wire adhere well, it is suitable for electrical equipment. The child becomes strong.

6. Heating applied to the armature winding can be completed only once, reducing deterioration of the wire due to heating.

7 The top surface of mold A protrudes from the top surface of mold B, and the mold is inserted and presses the commutator, and after sealing the top surface of mold A and the collar attached to the end of the commutator mold or the shaft, the resin is released. Since it is injected, even if there is a slight gap between the shaft and the shaft hole of mold A, resin flakes will not occur on the shaft part.

8. By providing a protrusion on the mold 7, it is possible to create a groove at the bottom of the cup, which increases the strength of the product and eliminates the gap in the clearance between the molds AB.

[Brief explanation of drawings]

Fig. 1 is a perspective view of an armature winding used in the armature of the present invention, Fig. 2 is a sectional view showing a method of manufacturing the armature of the present invention, and Fig. 3 is a cup-shaped electric machine manufactured according to the present invention. It is a sectional view of a child. 1... Armature winding, 3... Mold A, 4
...Shaft insertion hole, 6...Mold B,
7.12... Coil spring, 9... Mold C110... Mold D111... Commutator insertion hole, 14... Rectification child, t, 16...-
・Resin board. 5...Shaf

Claims (1)

[Claims] 1. A mold A having a shaft insertion hole in the center, and a mold B that is installed loosely on the outer periphery of the mold A to restrict the lateral movement of the mold A, from the upper surface of the mold B. an elastic body that urges the mold A so that the upper surface of the mold A protrudes; a mold C that is installed opposite the mold B; A mold is equipped with a commutator insertion hole in the center, a shaft is inserted into the shaft insertion hole of the mold A, and a thermosetting resin plate is inserted into the upper surface of the mold B. , an armature winding wound in a cup shape and connected to a commutator is inserted into the upper surface thereof, and then the mold C is moved in the direction of the mold B, and the commutator is molded with the mold. A, the commutator mold at the bottom of the cup was brought into close contact with the mold A, and then the mold C was pressed against the armature winding, and the armature winding was shaped into a predetermined shape and placed on the mold B. A method of manufacturing a cup-shaped armature, in which a resin plate is poured into a mold, and armature windings and a commutator are molded and fixed into a predetermined shape.