JPS6231347A - Method for connecting coreless motor coil with commutator - Google Patents

Abstract

PURPOSE:To make mechanically and electrically reliable contact by melting to remove the insulating film of a coil tap piece by smaller current in resistance welding process first of all and then by welding the coil tap piece to the edge of segment by a larger current. CONSTITUTION:At an edge of a cylindrical commutator the narrow edges of each segment bent and protruding outwards are pressed flatly. The flattened part thereof is formed into U-portion 12b by bending. Then, a coil tap piece 17, which protrudes inwards from the cylindrical coil edge, is calked and secured to the U-portion 12b. Then a resistance welding is performed. At this moment, the insulating film of the coil tap piece 17 is removed by a smaller current, then the coil tap piece 17 is welded to the segment edge by a larger current.

Description

Detailed Description of the Invention [Technical Field] The present invention relates to a method of connecting a cylindrical coil and each segment of a commutator in a coreless motor.

[Background technology 1] An example of a method for manufacturing this type of coreless motor coil is shown in the first example.
2 and 2, coil A is shown in FIG.
), a plurality of coil wire bundles 2 each formed by bundling a plurality of coil wires 1 into a sheet shape are arranged in parallel to form a cylinder, and each coil wire bundle 2 is separated by leaving both ends thereof. The inner cylinder 3 formed by twisting in one direction (arrow) and the outer cylinder 4 formed by twisting in the opposite direction (arrow) in the same way are superposed into two layers as shown in Fig. 1(e). The wave-wound coil A is formed by connecting the coil wires 1 of the inner and outer cylinders at the cylindrical end faces, and each coil is connected at the upper and lower ends of the coil A as shown in (f) and (g) in the same figure. Darkness FF for 2 questions about wire bundles
G is formed, and at the lower end, the connection between the coil wire bundles 2 and the connection to the commutator segment is made by the feeding connection coil wire 1a. Next, in order to join ±1 between the coil wires, first apply a mask 6 to a part of the end faces of both adjacent coil elements a1 of the inner and outer cylinders, and apply a heat-resistant insulating coating 8 to the other parts. Then, the mask 6 is peeled off and immersed in a solder bath, thereby filling the mask marks with the hang 7.

Figure 3 shows the structure of commutator B. As shown in (a) a cross-sectional view, (b) a bottom view, and (c) a perspective view, the core is made of a cylindrical resin molded product. The narrow part 11 of each segment 10 fixed to the outer peripheral surface of the material 9 is bent outward, and the bent part 12 is used as a coil tap connection part. ), first, a slit 14 is provided at the end edge of a short copper pipe 13 to form a narrow part 11, and this narrow part 11 is bent outward to form a bent part 12 as a tap connection part. After forming a core material 9 made of phenolic resin on this by insert molding, a slit 15 leading to the core material 9 is provided at the location indicated by the broken line on the surface of the copper pipe 13, and the copper pipe is formed as shown in Figure (c). It is separated into each segment 10.

As above, v! Conventionally, as a means for connecting the coalesced smoke coil A and the commutator B, a connecting member 16 made of a conductive plate is welded to the end face of the feeding connection coil wire 1a, as shown in FIG. 9(a). However, the other end of this connecting member 16 was laser welded to the bent portion 12 of the segment 10. However, this conventional method requires a separate member as the connecting member 16, and in addition, it is necessary to irradiate the laser beam at 45 degrees as shown in FIG. However, there were disadvantages such as the position of the beam being shifted, the electrical conductivity of the welded part being insufficient due to the generation of bubbles due to the laser beam, and the mechanical strength being insufficient.

EObject of the Invention 1 The present invention has been made in view of the above points, and its object is to provide a method for connecting the coil and commutator of a coreless motor that can be mechanically and electrically connected reliably. It is on offer.

[Disclosure of the Invention] The method for connecting the coil and commutator of the coreless motor of the present invention is to flatten the narrow end of each segment that is folded outward at one end of the cylindrical commutator. a step of forming the flat part into a U-shape, a step of caulking and fixing a coil tap piece protruding inward from the edge of the cylindrical coil to the U-shaped part, and the caulking. The fixing part is resistance welded using a double-electrode screw, and in the above resistance welding process, the insulation film of the coil tap piece is first melted and removed using a small current, and then the segment end and the coil tap piece are welded together using a large current. By making the ends of the segments flat and wide, caulking and fixing the coil tap pieces, and then resistance welding, the electrical and v8
! It is characterized in that it connects reliably mechanically and also simplifies the process by removing the insulation coating of the coil tap piece during the welding process.

In the present invention, the structure of coil A and commutator B is tlS
This is as explained in FIGS. 1 to 3. Figure ff14 shows the NIt configuration of the coil tap piece 17, and Figure 1 (
The feeding connection coil wire 1a shown in f) is formed to be longer than the other coil wires 1, and then bent inward to form the coil tap piece 17. teeth(
b) As shown in the figure, when cutting with the coil end faces SI aligned, only the coil element M1a for feeding connection is bent in advance, and furthermore, in order to align the tips of the coil tap pieces 17 of the inner and outer cylinders. The coil tap piece 17 on the inner cylinder side is cut at 82.

FIGS. 5(a) and 5(b) show the shapes of the punch 18 and gouer 19 for pressing the bent portion 12 at the end of the segment 10 of the commutator B into a flat shape as shown in FIG. 5(e). Figures (e) and (d) show the pressing operation. The flat portion 12a thus formed is then deformed into a U-shape as shown in FIG. 6(e) using the punch 20 and V-die 21 shown in FIGS.
In order to achieve this, the corners of the punch 20 and the die 21 are rounded, and the segments 10 are made of a soft material made of copper containing 0.2% silver. Figure 7(a)
(b) shows a method of caulking and fixing the coil tap pieces 17 to the U-shaped portion 12b. In this way, the two coil tap pieces and the end of the segment can be connected using a separate connecting member. You can connect without any problem.

FIG. 8(,) shows a method of further resistance welding the coil tap piece 17 and the U-shaped portion 121 which have been caulked and fixed as described above between the welding electrodes 22 and 23. Since an insulating film is formed on the circumferential surface of each coil wire 1 or 1a, first a small current is passed between both electrodes 22 and 23, and the joule of current flows through the segment end 12c bent in a C-shape. The insulation film on the circumferential surface of the coil tap piece 17 is melted and removed by heat generation, and then the filter tap piece 17 and the C-shaped portion 12c are welded together by a large current. In addition, as shown in FIG. 2(b), a recess 24 into which the 'h-sealing fixing part 12 cm 17 is fitted is formed in at least one of the electrodes 23, so that the caulking fixing part is pinched by both electrodes 22 and 23. Then both members 12c can be welded during welding.
, 17, the electrical conductivity of the welded portion can be improved, and the pre-process caulking process can be simplified. In this case, the depth of the recess 24 needs to be slightly smaller than the thickness of the caulking fixing part.

[Effects of the Invention] As described above, the method of the present invention includes the steps of press-forming each commutator segment R1 portion protruding from an external force into a flat shape, and bending this flat portion into a U-shape. , consisting of a step of caulking and fixing a coil tap piece protruding inward from a cylindrical coil to the U-shaped part, and a process of resistance welding the caulking fixing part between both electrodes, and in the resistance welding process. First, the insulation film of the coil tap piece is melted and removed using a small current, and then the segment end and the filter tab piece are welded together using a large current. Therefore, the coil tap piece and the commutator segment are electrically and mechanically bonded together. In addition to being able to connect reliably, the insulation film of the coil tap piece can be removed during the welding process, which has the advantage of significantly simplifying the process.
There is.

[Brief explanation of drawings]

Figures 1 to 8 show examples of the method of the present invention. Figure 1 is an explanatory diagram showing the manufacturing process of the coil used in the present invention, and the tjSQ diagram shows the process of connecting the coil wires together. The explanatory diagram shown in Figure @3 shows the manufacturing process of the commutator used in the present invention, (,) is a cross-sectional view, (b) is a bottom view, and (c) is a cross-sectional view.
is a perspective view of the main part, (d) is an explanatory diagram of the manufacturing process, and Fig. 4 (a)
5 is a perspective view of a coil tap piece, (b) is an explanatory diagram of the processing process of a filter tab piece, FIG. b) is a cutaway sectional view, (c) and (d) are explanatory diagrams of the pressing process, (e) is a perspective view of the main part after pressing is completed, and Fig. 6 shows the bending process of the segment end. (a) is a perspective view of the punch and die, (b) is a cutaway and sectional view thereof, (
C) (d) is an explanatory diagram of the bending process, (e) is a perspective view of the main part after completion of bending, tjS7 figures (a) and (b) are explanatory diagrams of the caulking process, and Figure 8 (a) shows the welding process. A sectional view, (b) is a sectional view showing another example of the welding electrode, fjS9 shows a conventional example, (a) is a perspective view of the main part, and (b) is a side view of the main part. . A is a coil, B is a commutator, 10 is a segment, 11 is a narrow part, 12 is a segment end or bent part, 12a is a flat part, 12b is a U-shaped part, 12c is a C-shaped part, 17 is a Coil tap piece, 22.23 is welding electrode, 24 is four parts. Agent Patent Attorney Ishi 1) 艮 7th Figure 1 (f) @2 Figure 3

Claims (2)

[Claims] (1) a step of flattening the narrow end of each segment bent outward at one end of the cylindrical commutator, and a step of bending the flattened portion into a U-shape; The above-mentioned resistance welding step consists of a step of caulking and fixing a coil tap piece protruding inward from the edge of the cylindrical coil to the U-shaped portion, and a step of resistance welding the caulking fixing portion between both electrodes. A method for connecting a coil and a commutator of a coreless motor, characterized in that the insulating film of the coil tap piece is first melted and removed using a small current, and then the segment end and the coil tap piece are welded together using a large current. (2) A coil for a coreless motor according to claim 1, wherein a recess into which the caulking fixing part fits is formed in at least one of both electrodes, and the caulking fixing part is pinched by both electrodes. How to connect a commutator.