JPS609419B2 - Manufacturing method of armature of rotating electric machine - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an improvement in a method for manufacturing an armature of a rotating electrical machine using a flat coil.

First, the armature of a conventional rotating electric machine will be explained with reference to FIGS. 1 to 3. Figure 1 shows the main parts of a conventional armature.
1 is a shaft, 2 is an armature core that is press-fitted into this shaft 1 and has a slot on its outer periphery, and 3 is also a shaft 1
3A is the riser part of the segment to which the armature coil is connected, 3 is the segment for connecting the armature coil provided in this riser part 3A. It's a groove. 4 and 5 are armature coils wound in the slots of the armature core 2, 4A is a lower outlet of this armature coil 4, and 5B is an upper outlet of the other armature coil 5. As shown in FIGS. 2 and 3, these are inserted into the grooves 3B provided in the riser section 3A and connected by brazing, welding, or other methods.

FIG. 2 is a sectional view taken along the line 0--RO in FIG. 1, and 6 is a molded resin annular body constituting the commutator 3.

FIG. 3 is a sectional view taken along the plate-m line in FIG. 1.

As is well known in this conventional armature structure, the commutator 3 manufactured in a separate process is press-fitted into the shaft 1, and the lower outlet part 4A of the armature coil 4 inserted into the armature core 2 is connected to the first As shown in the figure, the upper exit part 5B of another armature coil 5 is twisted in the opposite direction by the same angle, and these are twisted in the same riser groove. 38 and fixed by caulking, brazing, welding, or other methods.

In this conventional method, the commutator 3 is manufactured in dozens of steps, so it is expensive, and the armature coil 4,
When connecting the outlet parts 4A, 5B of 5 and the riser part 3A, it is necessary to process a groove 3B in this part. There were drawbacks such as the need to swage the parts in advance, and particularly careful work was required to withstand centrifugal force, high temperatures, vibrations, etc. during use.

This invention was made in order to eliminate the above-mentioned drawbacks of the conventional products, and an object of the present invention is to provide an excellent method of manufacturing an armature for a rotating electric machine as described below.

An embodiment of the present invention shown in FIGS. 4 to 11 will be described below.

In each figure, 41A is the lower outlet of the armature coil 4 which is an axial extension of the outlet which is the outlet conductor of the armature coil 4, and 51B is the upper outlet of the armature coil 5. Debe, 4
0 is a segment portion 6a which is a conductive portion of the commutator obtained by twisting the lower outlet portion 41A by 900 degrees.
is a groove provided on the outer periphery of the resin annular body 6 into which the lower outlet portion 41A of the armature coil 4 is press-fitted; 7 is a power feeding brush that comes into sliding contact with the segment portion 40; 8 is an ultrasonic wave A tip of the press-fitting device, 9 an ultrasonic welding device, 10' a power source for Mako's device, turtle 1 a coil energized by this power source, 12 a magnetostrictive vibrator that generates ultrasonic vibrations by energizing this coil; 13 is a horn that increases the vibration of this vibrator ~ 14 is connected to this horn and presses the upper outlet part 51B of the armature coil 5 to press each outlet part 41A, 5
18 is a chip for ultrasonic welding, 15 is an outer peripheral part of the upper outlet part 51B of the coil 5, and a powder-like insulation at room temperature is filled in the gap between this outlet part 518 and the outer peripheral part of the commutator. The resin body is made of epoxy resin, etc.

Next, a method for manufacturing the armature of this embodiment will be explained.
The lower outlet part 41A of the armature coil 4 is connected to the armature coil 5.
It is set longer than the upper mouth side outlet part 51B. Furthermore, grooves 6a into which the lower outlet portions 41A are press-fitted are formed in the outer circumferential portion of the resin annular body 6 of the commutator. Then, only the lower outlet part 41A is twisted 900 degrees from the tip by a predetermined length to form the segment part 40 of the commutator. Next, this segment portion 40 is press-fitted and fixed into the groove 6a of the resin annular body 6 by ultrasonic press-fitting. In this ultrasonic press-fitting process, as shown in FIG. It is press-fitted and fixed inside. Thereafter, the outlet portion 51B is twisted in the circumferential direction and held on the segment portion 40 as in the conventional case. Thereafter, the outlet portion 51B and the segment portion 40 are welded and integrated using the ultrasonic welding device 9. (This welding process is shown in FIGS. 8 and 9.) After this, epoxy resin 15 is filled and fixed on the outer circumference of the commutator excluding the segment portion 40 and on the outer circumference of the upper outlet 51B. let That is, in this embodiment, the lower end portion 41A of the armature coil 4 is extended,
Since this extended portion is press-fitted and fixed to the outer circumferential portion of the resin annular body 6 to serve as a sliding portion for the power feeding brush 7, commutator segments are not required, and the manufacture of the commutator becomes extremely easy.

In addition, "resin annular body 6 at the extension part of the lower mouth side outlet part 41A"
can be fixed to the groove 6a in a short time by ultrasonic press-fitting, and the connection between the lower outlet part 41A and the upper outlet part 51B can be firmly and quickly fixed by ultrasonic welding. It is possible to provide an armature with high productivity, such as that which can be carried out at Furthermore, in the above embodiment, each outlet portion 41A, 5
The outer periphery of 1B and the outer periphery of the commutator except for the segment portion 40 are filled and fixed with epoxy resin 15.
The insulation properties of each of the □ projecting portions 41A and 51B as well as the mechanical strength associated with the rotation of the armature can be set to be sufficiently high. In this invention as described above, a pair of flat coil outlet portions of the armature coils wound respectively in the slots of the armature core are arranged to be substantially orthogonal to each other, and the inner circumferential side of the coil outlet portions that are substantially orthogonal to each other is arranged. Extend the outlet part of the inner circumferential side in the direction of the ball, and fix this extended inner circumferential side coil outlet part to the outer circumferential part of the resin annular body of the commutator by ultrasonic press-fitting. After fixing the coil exit part on the outer peripheral side by ultrasonic welding and configuring the inner peripheral side coil exit part to become a conductive part on which the power supply brush can slide, each coil excluding the conductive part is Insulating resin is filled and fixed between the outer periphery of the outlet and each coil outlet, which not only eliminates the need for expensive commutator segments that were previously prepared separately, but also eliminates the need for particularly elaborate commutator segments. The work required to connect the armature coil outlet and the commutator segments can be eliminated, and the resin annular shape of the inner coil outlet, which forms the conductive part of the commutator, can be eliminated. Press-fitting into the body and ultrasonic welding between a pair of coil exits can be performed extremely easily in a short time, and the insulation of the coil exit and mechanical strength due to the action of centrifugal force are sufficient. In addition, by fixing the inner coil outlet part to the outer circumference of the resin annular body of the commutator by ultrasonic press-fitting, the inner coil outlet part, which becomes the conductive part of the commutator, can be set to a high height. Since it can be fixed to the resin annular body in a short time and reliably, the armature of the rotating electric machine can be secured at low cost and with high reliability.

[Brief Description of the Drawings] Figure 1 is a front view showing the main parts of a conventional armature, Figure 2 is a sectional view taken along the Rolo line in Figure 1, and Figure 3 is a sectional view taken along line mm in Figure 1. , FIG. 4 is a front view showing the main parts of the armature in one embodiment of the present invention, FIG. 5 is a sectional view taken along line V--V in FIG. 4, and FIG.
The figure is a sectional view taken along the line 1 in Fig. 4, Fig. 7 is a sectional view showing the ultrasonic press-fitting process in the embodiment shown in Fig. 4, and Figs. 8 and 9 are sectional views in the embodiment shown in Fig. 4. A sectional view showing the ultrasonic welding process, FIG. 10 is a sectional view showing the armature after filling and fixing the insulating resin in the embodiment shown in FIG. 4, and FIG. 11 is a sectional view taken along the phantom line in FIG. 10. It is. In the figure, 1 is a shaft, 2 is an armature core, 3 is a commutator, 30 is a segment, 3A is a riser part, 3B is a groove, 4
40 is the armature coil, 40 is the segment portion, 4A is the lower outlet of the armature coil, 5 is the armature coil, 5B is the upper outlet of the armature coil, 6 is the resin annular body, 6a is the groove, 7
8 is a power supply brush, 8 is a tip of an ultrasonic press-fitting device, 9 is an ultrasonic welding device, and 15 is an insulating resin body. Note that the same reference numerals in each figure indicate the same or corresponding parts. 1st
Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11

Claims (1)

[Claims] 1 A pair of flat coil outlet portions of the armature coils respectively wound in the slots of the armature core are arranged so as to be substantially orthogonal to each other, and an outlet portion on the inner peripheral side of the substantially orthogonal coil outlet portions is arranged. is extended in the axial direction, and the extended inner coil outlet is fixed to the outer circumference of the resin annular body of the commutator by ultrasonic press-fitting, and the inner coil outlet and the outer coil are After fixing the coil outlet portions by ultrasonic welding and configuring the coil outlet portion on the inner peripheral side to become a conductive portion that the power feeding brush can come into sliding contact with, each coil outlet portion other than the conductive portion is 1. A method of manufacturing an armature for a rotating electrical machine, characterized in that an insulating resin is filled and fixed between the outer peripheral portion and each of the coil outlet portions.