JPS6314579B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Field of Industrial Application) The present invention relates to an improvement in a method of manufacturing a commutator for a flat motor.

(Prior Art) As shown in Figs. 1 and 2, a flat type commutator 1 has recently been proposed for a flat motor. A plurality of segments 4 made of a highly conductive material and having a connecting piece 3 rising from the piece 2 and forming an electrically integrated unit are installed in a ring shape, and the segments are insulated from each other by an insulating material 5. The segment 4 and the amateur coil 7 are connected by pushing the connecting wire 8 of the amateur coil 7 into a cut groove 6 formed by cutting the top of the piece 3.

However, this type of flat commutator 1
are expensive because they are difficult to manufacture. Therefore, conventionally, for the purpose of cost reduction, a method has been adopted in which a flat type commutator is manufactured through four steps shown in FIGS. 3 to 6 below.

In this method, in the first step, as shown in FIG. 3, the inner peripheral part of the annular disk 9 made of a highly conductive material is raised up by press drawing, and the inner peripheral part of the outer annular flat plate part 10A is raised. A cylindrical portion 10B is formed in the cylindrical portion 10B.

Next, in the second step, as shown in FIG.
to form a plurality of connecting pieces 3 extending in the axial direction.

Furthermore, in a third step, synthetic resin as an insulating material 5 is molded on the inner and outer peripheries of the annular disk 9 processed as described above, as shown in FIG. 5, to form an integrated insulating body 12. .

Finally, in a fourth step, as shown in FIG.
The annular flat plate portion 10A is cut into a plurality of parts to form fan-shaped sliding contact pieces 2 by making cuts opposite to the slits 11 at B, and the surfaces of these sliding contact pieces 2 are used as brush sliding surfaces 14.

Thus, each of these sliding contact pieces 2 is integral with each of the connection pieces 3, adjacent ones are insulated from each other by the slits 11 and 13, and each constitutes one independent segment 4, and these segments 4 are arranged annularly in the radial direction and integrated by the insulating material 5 in which the slits 13 of the insulating integrated body 12 are not cut.

(Problems to be Solved by the Invention) However, the commutator 1 manufactured in this way has a weak strength because the thickness of the connecting piece 3 is about 0.7 mm to 1.0 mm, which is almost the same as the plate thickness.
It was not possible to apply strong force when connecting to amateur coil 7.

For example, even when applying pressure and applying current to connect the commutator 1 and the connecting wire 8 by heat fusion, there is a risk that sufficient force cannot be applied and the connection force will be extremely weak. .

Furthermore, in the case of connection by soldering, since the melting point of the solder is low, it cannot be used in this type of motor which is exposed to high temperatures.

Furthermore, in the case of connection by brazing, there is no problem in terms of temperature, but it is necessary to heat the commutator 1 until the solder melts, and in that case, the insulating material 5
There are problems such as melting of the synthetic resin or tearing of the insulating film of the connecting wire 8, and the high temperature makes workability poor and there is a risk of high cost.

The present invention has been made in view of the above circumstances, and provides a commutator for a flat motor that can easily and quickly connect the connecting wire of the armature coil and the connecting piece of the commutator at low cost. The purpose is to provide a manufacturing method.

[Structure of the Invention] (Means for Solving the Problems) In order to achieve the above-mentioned objects, the present invention has the following features: (a) The inner peripheral portion of an annular disk made of a highly conductive material is formed by press drawing. (b) At the same time or after that, the top of the cylindrical part is bent inwardly or outwardly to form an inverted U-shaped cross section. (c) cutting slits at regular intervals in the circumferential direction from the inverted U-shaped section toward the base of the cylindrical section to form a plurality of connecting pieces extending in the axial direction; ) An integrated insulating body is formed by molding synthetic resin as an insulating material on the inner and outer peripheries of the disk consisting of the cylindrical part and the annular flat plate part; A plurality of radial slits are cut into the annular flat plate portion so as to face the slits in the cylindrical portion, and a plurality of fan-shaped sliding contact pieces are arranged radially on the bottom surface of the integrated insulating body. (f) an inverted U cross-section of each connecting piece of the segment;
(g) Each armature coil constituting the armature of the flat motor is arranged concentrically around the integrated insulating body, and the connecting wire of the armature coil is connected to the armature coil for the wire connection. (h) While heating the connecting wires of each armature coil and the connecting piece, pressing the connecting wires from the axial direction into the connecting grooves, The present invention is characterized in that a plurality of connection pieces each having a cut groove for connection are integrally connected to each other.

(Function) According to the method of the present invention, the top of the connecting piece in the commutator has a double structure, and its strength is improved. In addition, since the strength of the connecting piece is improved in this way, the connecting wire of each armature coil is heated and pressurized using the so-called hot steak method to form it on the top of the connecting piece from the axial direction. It can be pushed into the connection groove, and the connection between the armature coil connection wire and the commutator connection piece can be easily completed. Furthermore, since the connecting wire of the armature coil can be connected from the axial direction to the horizontally installed commutator, the manufacturing apparatus itself can be made compact.

(Example) Hereinafter, a commutator manufacturing method according to the present invention will be explained with reference to the drawings.

7 to 9 (the same members as in FIGS. 1 to 6 are given the same reference numerals) show an example of the same commutator 20, and the segments 21 constituting this commutator 20 are the same as those in the above-mentioned parts. Like the segment shown in FIG. 2, it has a fan-shaped brush sliding contact piece 2 and a connecting piece 22 rising from this brush sliding contact piece 2 and forming an electrically integrated body, and is made of a highly conductive material (for example, copper or copper alloy). It is constructed by

Note that "23" is a piece that prevents it from coming off during resin molding.

To manufacture such a commutator 20, as shown in FIG. 3, first, the inner peripheral portion of the annular disk 9 made of a highly conductive material is raised up by press drawing, and the outer annular flat plate portion 10A is formed. A cylindrical portion 10B is integrally formed on the inner periphery of the cylindrical portion 10B. Next, at the same time as or after the formation of the cylindrical portion 10B, the top of the cylindrical portion 10B is bent inward to form an inverted U-shaped cross section 22a. Then, slits 11 are cut at regular intervals on the circumference from the inverted U-shaped section 22a toward the base of the cylindrical section 10B, and connecting pieces 2 extend in a plurality of axial directions.
2 (see Figure 9).

Next, synthetic resin as the insulating material 5 is molded on the inner and outer peripheries of the disk 9 processed as described above.
An insulating integrated body 12 is formed. And the 7th and 8th
As shown in the figure, radial slits 13 are formed in the annular flat plate portion 10A exposed on the bottom surface of the integrated insulating body 12.
are respectively cut opposite to the slits in the cylindrical portion to form a plurality of fan-shaped sliding contact pieces 2 arranged radially on the bottom surface of the integrated insulating body 12. As a result, electrically mutually independent segments 21 consisting of the connecting piece 22 and the sector-shaped sliding contact piece 2 are formed. Further, as shown in FIG. 9, a connection groove 6 is formed in the inverted U-shaped section 22a of each connection piece 22.

If you manufacture a commutator in this way,
The part where the connecting wire 8 is connected is made of double plates with a thickness of 0.7 mm to 1.0 mm, and these are arranged in a ring shape with the insulating material 5 interposed therebetween. Therefore, the strength when connecting the connecting wire 8 is significantly improved.

If the strength of the top part of the commutator 20 is increased in this way, it can withstand high temperatures, so it becomes possible to use the so-called hot steak method. This hot steak method is a method in which the heated and softened connecting wire 8 is pushed into the cut groove 6 while applying pressure. Here, the method of heating the connecting wire 8 is to bring a high-temperature chip or the like into contact with the connecting wire 8 and heat it by thermal conduction, or to apply a large current to the connecting wire 8 while it is in contact with the kerf 6. This is a method in which water is passed through the water and heated using Joule heat.

Therefore, in the present invention, after the integrated insulating body 12 configured as described above is placed on a horizontal substrate (not shown), each of the armatures of the flat motor is placed around the integrated insulating body 12. The amateur coils are arranged concentrically, and the connecting wires 8 of the amateur coils are placed on the connection grooves 6. Then, as shown in FIG. 9, the connecting wires 8 and the connecting pieces 22 of each amateur coil are held with the same high-temperature chip or electrode chip, and each connecting wire 8 is inserted into the respective groove 6 in a downward direction while being heated. and push it in to connect the commutator 20 and armature coil 7. That is, using the so-called hot steak method, all connections are easily and quickly made at once. In this case, since the inverted U-shaped section 22a of the connecting piece 22 has sufficient pressure resistance, there is no risk of deformation of the commutator itself unlike conventional ones, there is no possibility of defective products, and the wiring work is easy. can be done.

In particular, in this way, an integrated insulating body 1 is placed on a horizontal substrate.
If the connecting wire 8 is simultaneously heated and pressurized from above while the amateur coils are placed and the amateur coils are arranged concentrically around it, there is also the advantage that the entire manufacturing apparatus can be made compact.

In the embodiment described above, the insulating integrated body 12 is placed horizontally and the plurality of connecting wires 8 of the armature coil 7 are connected at once, so that the commutator 20 can be manufactured extremely efficiently. In some cases, the connection lines 8 may be connected individually.

Further, the method of the present invention is not limited to the case where the integrated insulating body 12 is placed horizontally, but it is usually carried out with the integrated insulating body 12 placed horizontally as in the embodiment, and it is carried out in this way. case is most efficient.

In the above-mentioned embodiment, the inverted U-shaped section of the connecting piece 22 is folded inward, but the point is that the top of the commutator should have at least a double structure, and can be folded outward or inward. Needless to say, various methods such as folding in both directions can be considered.

[Effects of the Invention] As is clear from the above description, according to the present invention, the top of the connecting piece extending in the axial direction is bent or folded to form at least a double structure,
In order to improve the strength of the commutator, we adopted the so-called hot steak method in which the integrated insulating body is placed on a horizontal substrate and an armature coil is arranged in a ring concentrically with this integrated insulating body from the axial direction. Then, connect the connection wires of the multiple armature coils into the connection grooves in the commutator.
Since the wires are connected by pressing them under heat and pressure, the connection between the commutator and the armature coil can be made extremely firmly and quickly. Since there is no need to use connection materials such as solder, it is also advantageous in terms of cost.

Particularly when used in a mass production production line such as an automobile production factory, it has the excellent effect of eliminating process bottlenecks and making it possible to obtain an inexpensive commutator for flat motors by a simple manufacturing method.

[Brief explanation of the drawing]

Figure 1 is a schematic perspective view showing the armature of a conventional flat motor, Figure 2 is a perspective view showing one segment of the commutator of the armature, and Figure 3 is a perspective view showing one segment of the armature of the armature.
6 are diagrams showing the manufacturing process of the commutator, FIG. 7 is a perspective view showing an example of the segments of the commutator according to the present invention, FIG. 8 is a plan view of the commutator in which the segments are combined, and FIG.
The figure is a sectional view taken along the - line in FIG. 8. 2... Brush sliding contact piece, 5... Insulating material, 6... Cut groove, 8... Connection wire, 11, 13... Slit, 2
0... Commutator, 21... Segment, 2
2... Connection piece, 22a... Inverted U-shaped cross section.

Claims (1)

[Scope of Claims] 1 (a) The inner circumferential portion of an annular disk made of a highly conductive material is raised up by press drawing to integrally form a cylindrical portion on the inner circumference of the outer annular flat plate portion, (b) At the same time or after that, bend the top of the cylindrical part inward or outward to form an inverted U-shaped cross section; (c) From the inverted U-shaped cross section to the cylindrical part (d) cutting slits at regular intervals in the circumferential direction toward the base of the disk to form a plurality of connecting pieces extending in the axial direction; (e) forming a plurality of radial slits in an annular flat plate portion exposed on the bottom surface of the integrated insulating body, each facing the slits in the cylindrical portion; (f) forming an electrically independent segment consisting of the connecting piece and the sliding contact piece in which a plurality of fan-shaped sliding contact pieces are arranged radially on the bottom surface of the integrated insulating body by cutting; Cross-sectional inverted U in each connection piece of the segment
(g) Each armature coil constituting the armature of the flat motor is arranged concentrically around the integrated insulating body, and the connecting wire of the armature coil is connected to the armature coil for the wire connection. (h) While heating the connecting wires of each armature coil and the connecting piece, pressing the connecting wires from the axial direction into the connecting grooves, 1. A method of manufacturing a commutator for a flat motor, characterized in that a plurality of connection pieces each having a cut groove for connection are integrally connected.