JPS5961451A - Disk type commutator and manufacture thereof - Google Patents

Abstract

PURPOSE:To enhance the durability, surface hardness and mounting accuracy of a disk type commutator by providing partial hardness difference on rivet type commutator segments of T-shaped section formed by cold forging and securing both in the state that the segments are engaged with small holes of a disk type base plate. CONSTITUTION:The wedge head 6a of a commutator segment 9 worn without interval by a brush is formed by cold forging. The segment 8 is formed of a rivet of T-shaped section formed of the head 6 of wedge shape, a tail 7 and a terminal riser 8. This segment 9 is hardened only on the surface of the head 6a. On the other hand, the tail 7 to be caulked and mounted with lead wirings is maintained softly. This segment 9 is engaged with the small hole 12 of a disk shaped base plate 10, and both are then secured.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a commutator (commutator) used as an indispensable part for a direct motor, our electric machine, an AC commutator, etc., and a method for manufacturing the same.

More specifically, the present invention relates to a disk-shaped commutator that is suitable for being installed in thin devices such as flat motors or print motors.

The cylindrical commutator that has been used for many years is not only thick in the axial direction and takes up space, but also has the problem that each commutator piece is attached in the centripetal direction, which makes it easy to separate due to the centrifugal force that occurs as it rotates. However, in order to eliminate these inconveniences, a disk-type commutake has been proposed in recent years.

Conventional disk-type commutators are known in which each commutator piece is etched onto a printed circuit board, and in which each commutator piece is attached to a disk by press working.

However, the former, that is, the etched one,
Although it cannot be used for large currents, there is the problem that it is impossible to meet the requirements for a thickness of sufficient thickness for each commutator piece, for example, at least 12 pieces. Even with processed commutator pieces, there are restrictions on the thickness in order to be able to bend them smoothly, and it is also difficult to ensure that each commutator piece is in close contact with the disk as a uniform plane. The mounting itself tends to loosen or shift due to the action of centrifugal force caused by rotation, and as a result, there is a problem that accuracy is inevitably lowered.

It is an object of this invention to be able to produce commutator pieces having both thickness and surface hardness sufficient to withstand constant friction caused by brushes, by an extremely simple and inexpensive means, and at the same time M has created a disk-type commi-data and its manufacturing method that allows the piece to be firmly and evenly attached to a disk-type substrate without causing even the slightest deviation in the profit margin due to the action of centrifugal force caused by rotation. and provide it.

To summarize, Akira Motomoto's concept consists in that an iron commutator piece with a T-shaped cross section, processed by cold forging, is fitted into a small hole in a disk-shaped substrate, and the two are fixed together.

The depiction and operation of the invention will be explained in detail below with the aid of a diagram according to one specific embodiment thereof.

First, as shown in FIG. 4 (5) [F]), prepare a copper plate rod 5 with a predetermined width and thickness, and with the end face facing the longitudinal direction of the rod, use a header tool (not shown) to When struck, the head deforms to form an elliptical plate 6, and when cut across the middle of the tack 5, the tail 7 of the tack has a T-shaped cross section.
is created.

Therefore, as shown in FIG. 4(0), the elliptical plate 6 of the head is cut and formed into a wedge shape 6a, and a part of the tail 7 is removed to form a terminal protrusion 8.

Thus, the commutator piece 9 used between the main residences has a wedge-shaped head 6.
This is a tack with a T-shaped cross section, consisting of a tail part 7 and a terminal protrusion part 8.

The cross-sectional shape of the rod 5 may be elliptical or square in addition to the plate shape (FIG. 4A), but it is preferable that the rod 5 has a shape that does not move in the mounting direction.

The terminal protrusion 8 may be formed at one end, the other end, or the center of the tail.

The disk-shaped substrate 10 is made by punching an insulating plate material into a circular shape, and at the same time has a large hole 11 in the center for fixing the shaft, and a large number of small holes 12 of the same shape and size equally spaced from the center. 1
2 a, 12 b... are engraved.

The shape of the small holes is an elongated hole adapted to the tail portion 7 of the commutator piece 9, and they are arranged in rows along the radial direction of the substrate 10. If the shape of the tail portion 7 is oval or angular, the small hole is also made in a shape that conforms thereto.

After fitting each commutator piece 9 into these small holes 12.12a%12b... from one side of the board 10 to the other side by hand or machine, as shown in @4 Figure (2) like 1
With the head 6a of each commutator piece 9 in contact with the stand 13, use the concentric double cylindrical caulking chisel 14 to attach the two parts of the tail 7 of each commutator piece 9 at the same time. Dent 15.1
6.15a, 16a115b, 16b..., the pressing force of the chisel 14 causes deformation of the tail end surface by caulking in one step, and each commutator piece 9 has a small hole 12.12.
a, 12 b-8 is fixed to non-extractable NQ.

As another fixing means, it is also possible to apply a heat-resistant adhesive to the back surface of the substrate 10 to prevent each commutator piece 9 from slipping out of the small hole.

In the present invention, as described above, the wedge-shaped head 6a of the commutator piece 9, which is exposed to constant friction by the brush, is produced by cold forging, for example, by striking with a header, so that the thickness is, for example, 1.2 or more. It is extremely easy to process the material to make it thicker, and the surface hardness increases sufficiently due to the forging process, and the ideal hardness of Shore 22 to 24 can be created, so the durability is sufficient. Moreover, the above can be achieved reliably, quickly and easily by cold heading processing,
The device is also extremely simple and can be provided at low cost.

Furthermore, Hontakuma has adopted a method in which each commutator piece 9 is made into a rivet with a T-shaped cross section, and the iron-shaped commutator piece is fitted into the small hole 12 of the board 10 and then fixed. The installation is strong and there is no risk of it lifting up or coming loose. The surface of the wedge-shaped head 6a of each commutator piece is even and smooth, ensuring continuous smooth contact without the risk of causing trouble in the running of the brush. Since the displacement of each commutator piece 9 is reliably prevented by the outer end face of the small hole 12 due to the centrifugal force generated with rotation, there is no risk of destruction even by high-speed rotation, and the installation accuracy will be disturbed. maintained without any

[Brief explanation of the drawing]

The drawings illustrate one specific embodiment of the invention. Figure 1 is a front view, Figure 2 is a rear view, 5 Figure 3 is a vertical sectional view taken along line 3-3ff# in Figures 1 and 2, and Figure 4 is an explanatory diagram showing the processing procedure. . 5... Copper plate shell, 6... Oval plate, 6a... Wedge-shaped head, 7... @T-shaped stud tail, 8... Terminal protrusion, 9... Commutator Piece, 10...Substrate, 11...Large hole, 12.12 a, 12 b...Small hole, 13
-...stand, 14...concentric double cylindrical caulking chisel, 1
5.16.15 a, 16a, isb, 1
6b ・"Dent caused by caulking. Patent applicant: Mikasa Kinzoku Co., Ltd. Representative Patent Attorney Shigeru Sanne Representative Patent Attorney Mitsune Spine Diagram 1 Diagram 3 Diagram 2 Procedural Amendment (Teacher) Male 1980/January 1F11 2. (Patent 1i Commissioner Kazuo Nasugi 1 Neutral indication Patent application No. 171775 of 1982)
No. 2, Investigation C+) Name h Disk type commutator and its manufacturing method 3, Person making the amendment (11 I II, - concave (Series) Patent applicant (I Place (1,
:: Place) Air 1, 7. Wa 1, Mikasa Metal Co., Ltd. 4, Agent (249) 1-1-19 Sakurayama, Zushi City Telephone (0468)
) TI-28725, correction command (7) Eth = i
Showa $11 14 1'1 Day 6, Supplementary 11
Column 7 of the statement [detailed explanation of the first son]
Contents of Supplement 11 are listed below in the next IA f4. Turu spring 1,
The text from page 6, line 11 to page 7, line 3 of the specification is corrected as follows. [The surface of the commutator is originally in constant sliding contact with the carbon brushes, and the material used for the commutator is copper, which has excellent conductivity. However, steel is softer than other metals, and while this softness makes the material much easier to process, it also has the disadvantage that the sliding contact portions wear out significantly in a short period of time. The first objective of this research was to overcome the above-mentioned trade-offs and preserve the excellent properties of steel, such as its electrical conductivity and ease of workability, while at the same time improving the surface hardness of the parts that are in continuous sliding contact with the brush. An object of the present invention is to create and provide a disk-type commutator having commutator pieces that also has improved wear resistance and a method for manufacturing the same. The second purpose of this research is to be able to fabricate the above commutator pieces extremely easily and at low cost, and at the same time to be able to attach each commutator piece evenly and firmly to a disk-shaped substrate, and to use centrifugal force to To create and provide a disc-type commutator and its manufacturing method that do not cause any deviation in installation accuracy. To summarize Honkomei's concept, sliding contact of commutator pieces? ji
A rivet with a T-shaped cross section is processed by cold forging, for example, by hitting it with a header, and the hardness of only the surface of the head is high, but it is difficult to perform crimping, lead wire attachment, etc. The tail part that is treated remains as soft as before,
The commutator pieces having such local hardness differences are fitted into the small holes of the disk-shaped substrate and then fixed together. 2. On page 7, line 7, insert ``conductive material, for example'' before ``copper plate.'' 3. From the 9th negative line 10th line “for example...” to the 1st line
Correct the second line up to ``...easy'' as follows. ``As a result, even though the hardness of the sliding contact area is improved, the hardness of the caulked part of the board remains the same as before, so the entire process is easy without cracking due to caulking.'' 4, Ibid. No. 9 Page 14th line “Delete 1 of Shores 22 to 24.

Claims (9)

[Claims] (1) An insulating disk-shaped substrate with a large hole in the center for fixing the shaft and a large number of small holes of the same shape and size at equal distances and intervals from the center; and the substrate. A large number of conductive commutator pieces of the same shape and size and having a T-shaped cross section and having wedge-shaped heads respectively fitted into the large number of small holes from one side to the other side; and means for fixing the tails of the respective fitted commutator pieces to the substrate; (2) The commutator according to claim 1, wherein the small holes are long holes extending in the radial direction of the substrate. (3) The commutator according to claim 1, wherein the shape of each rectifying eight-tailed portion is such that a terminal protrusion is provided on the radial center side of the substrate at the tail portion. (4) The commutator according to claim 1, wherein, as the fixing means, a recess is formed by caulking in the tail portion of each commutator piece except for the terminal protrusion. (5) A commutator according to claim 4, in which two fixing recesses are provided for each commutator piece. (6) The commutator according to claim 1, wherein a heat-resistant adhesive is applied as a fixing means between the small hole and each commutator piece. (7) Cold forging the end face of a rod-shaped copper material to form a head with a T-shaped cross section, and cutting the end in a direction transverse to the middle part of the rod to form a tail, and then attaching a protrusion for a terminal. A rivet-shaped commutator piece processing process in which the excluded tail is deeply cut out and the head is shaped into a wedge shape, and an insulating board is punched into a circular shape, with a large hole for fixing the shaft in the center, and a center hole for fixing the shaft. A disk-shaped base machining process in which a large number of small holes of the same shape and size are punched out at equal distances and intervals from the board, and the commutator pieces are respectively inserted into all of the small holes from one side of the substrate to the other side. A method for manufacturing a disk-type commutator comprising the steps of: after fitting, a cylindrical caulking chisel is used to carve recesses into the tails 81 of each commutator piece at the same time; (8) The shape of the small hole is made into a long hole along the radial direction of the substrate,
71.4 using a copper rod with a width and thickness that can fit into the long hole.
A method for manufacturing a commutator according to claim 7. (9) A method for manufacturing a commutator according to claim 7, in which the terminal protrusion is provided on the radial center side of the board (rule: claim 7, in which cold heading is performed as cold forging) A method for manufacturing a commutator according to claim 7. αυ A method for manufacturing a commutator according to claim 7, in which two recesses are simultaneously carved in the tail of each commutator piece using a concentric double cylindrical caulking chisel. .