JPS6160666B2 - - Google Patents

Description

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

In manufacturing a conventional cup-shaped coreless armature, the armature winding is first wound using 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, this method requires a very long time (more than 1 hour) for heating and curing because the solution viscosity is very low.
It requires many molds and a heating furnace, and furthermore, it requires a lot of work time for resin injection and removing burrs, so it is not suitable for mass production. , parts such as air bubbles where resin was not injected occurred, weakening the strength of the armature and causing quality problems.

As a means to improve the above 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 assembled and injected 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 is injected under pressure, so 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 deform, or lead wires to the commutator to break, or the winding to There were problems such as shooting because the parts were placed in close contact with each other.

The present invention solves all the problems of the above conventional methods, and will be explained below with reference to the accompanying drawings. First, as shown in FIG. 1, an armature winding 1 is provided, which includes a predetermined number of coil bundles made by winding a predetermined number of self-fused wires using a winding jig. Note that 2 is a lead wire connected to the commutator.

Next, as shown in FIG. 2, a resin plate 4 made of A-stage (raw resin) thermosetting resin kneaded together with additives and configured into a disk shape is placed on the heated A mold 3, and from above the resin plate 4 is placed. The armature winding 1 is inserted together with the commutator 5 and shaft 6 connected to the lead wire 2, and then the heated mold B 7 is inserted from above. As the B mold 7 is inserted, the armature winding 1 is shaped into a predetermined size. Next, before the B mold 7 is completely inserted into the predetermined position, C
The mold 8 is pushed up from below to shape the coil end portion of the cup opening, and the B mold 7 is further inserted to a predetermined position. At the same time, the resin plate 4
The resin is melted and filled into the space formed by the molds A, B, and C while wetting the armature winding and sliding it. The above condition is maintained for several minutes to harden the resin, and then the B mold 7 is removed and the completed armature as shown in FIG. 3 is taken out. Note that 9 is a protective cap provided to prevent the resin from adhering to the undercut portion and outer periphery of the commutator.

In the above embodiment, the resin plate 4 was provided between the cup bottom of the armature winding 3 and the armature winding 1, but the resin plate 4 was provided between the cup bottom of the armature winding and the B mold 7, or between the cup opening and the C mold. Needless to say, the same result can be achieved even if the space is set between 8 and 8. Further, although the above embodiment uses A-stage resin, B-stage (semi-cured) resin may be used in order to shorten the curing time. Of course, in order to further shorten the length, the resin plate may be preheated.

Furthermore, in the above embodiment, the shaping of the armature winding 1 and the resin injection were carried out simultaneously in the same mold, but it goes without saying that the shaping and resin injection of the armature winding 1 may be carried out in separate molds. may be inserted and fixed after the resin has hardened. Furthermore, magnetizable permanent magnet powder such as barium ferrite may be mixed with the resin.

As described above, a disc made of thermosetting resin is provided at the bottom of the cup of a winding shaping mold, and an armature winding with a shaft commutator attached is inserted into the heating mold. The winding is shaped by tightening it from above and below, and as soon as the shaping is almost completed, the heated and softened resin flows into the winding and hardens, so when the mold is opened, the armature hardened with resin can be taken out. It becomes possible.

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 resin that is unnecessary is zero. This reduces the cost of the resin.

3. Resin is injected into the armature winding at a slightly higher pressure than normal pressure, making it wet and sliding, and the winding is fixed with the resin in a short time, making it easy to work with, and preventing armature winding from shorting, breaking, or bending. etc. does not occur at all.

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

5. A-stage (raw resin) can be used as the resin material, so it has good compatibility with the self-bonding coating or insulation coating applied to the electric wire, and the resin and the electric wire adhere well, making it 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.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of an armature winding used in the armature of the present invention, FIG. 2 is a cross-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, 4... Resin plate, 3, 7, 8
……Mold.

Claims (1)

[Scope of Claims] 1. An armature winding, a commutator and At the same time as installing the shaft, a thermosetting molding resin member is installed so as to be located at the cup opening or bottom of the armature winding, and then the mold is pressed from above and below to shape the winding, and at the same time A cup-shaped iron core characterized in that a resin of the molding resin member is flowed into a space formed by the mold, and the resin is cured to integrally fix the armature winding, commutator, and shaft. Method of manufacturing armature. 2. The method of manufacturing a cup-shaped coreless armature according to claim 1, wherein the molding resin member is formed into a disk-shaped pellet by punching it into a plate shape. 3. The method of manufacturing a cup-shaped coreless armature according to claim 1, wherein the molding resin member is made by mixing resin with magnetizable permanent magnet powder.