KR20120002688U - Rotor for an electric motor - Google Patents

Abstract

The present invention relates to a rotor for an electric motor, the rotor comprising a rotor shaft (1), a rotor coil (2) and a commutator (3). The rotor coil 2 consists of an insulator, in particular a coiled wire with a lacquer insulator, the commutator 3 comprising a commutator sheet 4 and a commutator hook 5 for the coil end 6 of the rotor coil 2. It is formed as a hook commutator. The coil end 6 is engaged with the hook inner surfaces 7, 8 of each commutator hook 5 by a high temperature caulking method. According to the present invention, the one or more inner surfaces 7, 8 of the commutator hook 5 cause point and / or line stresses on the coil ends 6 upon engagement with the respective coil ends 6, so that the intended It has a surface structure which causes damage, in particular separation of the insulator of the coil end 6.

Description

Rotor for electric motor {ROTOR FOR AN ELECTRIC MOTOR}

The present invention relates to a rotor for an electric motor according to the preamble of claim 1, an electric motor according to the preamble of claim 6, and a manufacturing method of the rotor according to the preamble of claim 7.

The rotor for the electric motor includes a rotor shaft, a rotor coil and a commutator. The rotor usually interacts with the stator. The electric motor is a direct current motor or a general purpose motor.

The known rotor DE 100 42 512 A1, which is based on the present invention, has the above configuration. The contact of the rotor coil to the commutator is important here.

In known rotors, the rotor coils consist of coiled wire with lacquer insulation to avoid short circuits between the individual windings of the rotor coil. For contacting the coil ends, the commutator is formed as a so-called "hook commutator". Such hook commutator comprises on the one hand a commutator sheet for engagement with the commutator brush and on the other hand a commutator hook for engagement with the coil end of the rotor coil.

For contacting, the coil ends are each placed around one commutator hook and then joined with the hook inner surface of each commutator hook by a high temperature caulking method. During high temperature caulking, each commutator hook is bent, thereby fixing each coil end in the commutator hook. At the same time, the coupling is heat treated here by application of a voltage. The heat generation first causes a separation of the lacquer insulator and then a welding-like coupling between the coil end and the commutator hook.

A disadvantage of known rotors is that the energy use required for the separation of lacquer insulators is large before actual high temperature caulking. In addition, separation of the insulator at the coil end in the region adjacent to the commutator hook cannot be excluded, which can cause a short circuit between adjacent commutator sheets.

It has also been proposed to perform a separate thermal and / or mechanical treatment to separate the lacquer insulator prior to high temperature caulking at the coil end (WO 90/04864 A1). In addition to sparking at the coil end, brushing or blasting of the coil end to separate the lacquer insulator is presented. All these methods are complex in structure and / or energy.

The task of the present invention is to form and improve the known rotors such that the insulation of the coil wires in the region of the commutator hook is solved in an intended and structurally simple and energy-efficient manner.

The problem is solved by the features of claim 1 in the rotor according to the preamble of claim 1.

In particular, during bending of the commutator hook, the commutator hook is formed so that the insulator damage and / or detachment of the coil end can occur in the direct area of the commutator hook by a mechanical pressure fit coupling between each commutator hook and each coil end. It is important. In particular, the one or more hook inner surfaces of the commutator hook have a surface structure that causes point and / or line stresses on the coil ends upon engagement with each coil end. Point and / or line stresses cause the intended damage, preferably separation of the insulator at the coil end.

For the implementation of the surface structure, many preferred variants are possible. This is the subject of claims 2 to 5.

In a particularly preferred embodiment according to claim 3, the surface structure has one or more edges and / or vertices projecting in the direction of each coil end. In this way, the elevated stress on the coil end can be realized in a simple manner.

According to another lesson, which has its own meaning, the task is achieved by an electric motor according to claim 6.

The electric motor includes the rotor and also includes conventional components such as stators, yoke packets and the like. Embodiments of the rotor according to the present invention can be referred to the full range.

According to another lesson in its own sense, a method of manufacturing the rotor according to claim 7 is claimed.

In the method according to the present invention, it is important that point or line stress is provided at each coil end through the hook inner surface of each commutator hook before and / or during high temperature caulking for damage and / or separation of the insulator. .

By means of the present invention, a rotor is provided in which the insulation of the coil wire in the region of the commutator hook is intended and solved in a manner that is simply structurally desirable and in terms of energy.

In the following, the present invention is described in detail by way of examples.

1 is a side cross-sectional view of the upper half of the rotor according to the present invention.
FIG. 2 is a cross-sectional view along line AA of FIG. 1 of four embodiments a), b), c) and d) of the commutator according to FIG. 1 and a plan view along line BB.

The rotor shown in the figure is assigned to an electric motor, which can be formed as a pure direct current motor or as a general purpose motor. The electric motor is preferably assigned to the motor vehicle. Here, the electric motor can preferably be used in the category of automotive locks, in particular in the field of central locking drives, open drives or traction assist drives. Other preferred fields of use are window lift drives, sliding loop drives, motorized seat adjusters, transmission actuators, flap drives and door drives.

The rotor typically comprises a rotor shaft 1, a rotor coil 2 and a commutator 3. The rotor coil 2 consists of a coil wire with an insulator. The insulator is here and preferably lacquer insulator.

The commutator 3 is formed as a hook commutator and comprises a commutator sheet 4 and a commutator hook 5 for the coil end 6 of the rotor coil 2. Here, the "coil end" is to be understood broadly and includes the coil start in a narrower sense along with the coil end. In this sense the commutator hook 5 can be assigned to one or several coil ends 6.

The coil ends 6 are here engaged with the hook inner surfaces 7, 8 of each commutator hook 5 in a high temperature caulking method. The configuration of the rotor thus far corresponds to known prior art.

According to the present invention each one or more of the hook inner surfaces 7, 8 of the commutator hook 5 causes point and / or line stresses at the coil ends upon engagement with the respective coil ends 6, so that intended damage, In particular, it has a surface structure which causes the removal of the insulator of the coil end 6.

In general, the surface structure can be realized by providing one or more convex and / or concave forming portions. Particularly preferred variants are shown in FIG. 2.

One or more hook inner surfaces 7, 8 protruding in the direction of each coil end 6 and / or one or more vertices 10 protruding in the direction of each coil end 6. With a surface structure comprising, particularly good results for the separation of the insulators are achieved. The edge 9 preferably extends substantially perpendicular to the extension of each coil end 6 in the region of the hook inner surfaces 7, 8. 2a) shows an embodiment with a single edge 9. In contrast, in the case of the embodiment shown in FIG. 2 b) a plurality of edges 9 are provided which are parallel to each other.

However, the surface structure of one or more hook inner surfaces 7, 8 may have a face pattern that repeats periodically. An example of this is a knurled surface structure. This is illustrated by way of example in FIG. 2D).

FIG. 2C shows the surface structure of one or more hook inner surfaces 7, 8 with a single concave forming part each forming one edge 9 laterally. There are also basically provided a number of concave forming parts. The concave forming part or concave forming parts extend here and preferably substantially perpendicular to the direction of extension of each coil end 6 in the form of a channel.

Finally, it is possible for one or more of the hook inner surfaces 7, 8 to have a high roughness surface structure. As a result, elevated point stresses can be generated, and the respective stress points are placed very close to each other.

According to another lesson with its own meaning, an electric motor with the rotor is claimed. Embodiments of the rotor according to the present invention can be referred to the full range.

According to another lesson with its own meaning, a method of manufacturing the rotor is claimed. It is important that the damage of the insulation of the coil end 6 takes place before and / or during the high temperature caulking of the coil end 6 and the hook inner surfaces 7, 8 of each commutator hook 5.

As indicated in the above description, the separation of the insulator from the coil end 6 is realized in a simple manner and with low energy consumption in accordance with the present invention. In a suitable design, since at least a certain amount of isolation of the insulator can be carried out before high temperature caulking, the energy consumption required during high temperature caulking can be significantly reduced. In addition, it is desirable that the insulation be damaged only where necessary, i.e. only in the direct region of the hook inner surfaces 7,8. Thus, since there is no risk of short circuit between the coil ends of the two adjacent commutator sheets 4, the spacings between the commutator sheets 4 can be kept small. For this reason, the commutator is made small overall. Complex alignment after hot caulking used to ensure a sufficiently large gap between the commutator sheets can be omitted.

Finally, the contact resistance between the coil end 6 and the commutator hook 5 can be reduced by the solution according to the invention, in particular the hook inner surfaces which occur or in some cases irrespective of the thickness variation of the lacquer insulator. It can be reduced irrespective of the oxidation of (7, 8).

1 rotor shaft
2 rotor coil
3 commutator
4 commutator lamination
5 commutator hook
6 coil ends
7, 8 hook inner surface

Claims (7)

As a rotor for an electric motor, the rotor comprises a rotor shaft (1), a rotor coil (2) and a commutator (3), the rotor coil (2) being made of coiled wire with insulators, in particular lacquer insulators The commutator 3 comprises a commutator hook 5 and a commutator sheet 4 for the coil end 6 of the rotor coil 2 as a hook commutator, the coil end 6 having a high temperature caulking method. In the rotor for the electric motor, coupled with the hook inner surfaces 7, 8 of each commutator hook 5,
Each of the one or more hook inner surfaces 7, 8 of the commutator hook 5 causes point and / or linear stress on the coil end 6 upon pressure fit engagement with each coil end 6. A rotor for an electric motor, characterized in that it has a surface structure which causes the intended damage, in particular separation, of the insulator of the coil end (6). 2. Rotor according to claim 1, characterized in that the at least one hook inner surface (7, 8) has a surface structure comprising at least one convex and / or concave forming part. 3. The at least one hook inner surface (7, 8) according to claim 1, wherein at least one of the at least one edge (9) and / or each coil end (6) protrude in the direction of each coil end (6). A rotor for an electric motor, characterized in that it has a surface structure comprising one or more vertices 10 protruding in the direction of. 4. Rotor according to one of the preceding claims, characterized in that the at least one hook inner surface (7, 8) has surface structures in the form of a knurling. 5. Rotor according to any one of the preceding claims, characterized in that the at least one hook inner surface (7, 8) has a surface structure with high roughness. An electric motor with a rotor, the rotor comprising a rotor shaft (1), a rotor coil (2) and a commutator (3), the rotor coil (2) having an insulator, in particular a coil with lacquer insulator Consisting of a wire, the commutator 3 comprising a commutator hook 5 and a commutator sheet 4 for the coil end 6 of the rotor coil 2 as a hook commutator, the coil end 6 having a high temperature In the electric motor with a rotor, which is engaged with the hook inner surfaces 7, 8 of each commutator hook 5 by a caulking method,
Each of the one or more hook inner surfaces 7, 8 of the commutator hook 5 generates point and / or line stresses on the coil end 6 upon pressure fit engagement with each coil end 6. An electric motor with a rotor, characterized in that it has a surface structure which causes intentional damage, in particular separation, of the insulator of the coil end (6). A method of manufacturing a rotor for an electric motor, the rotor comprising a rotor shaft (1), a rotor coil (2) and a commutator (3), the rotor coil (2) having an insulator, in particular a lacquer insulator Consisting of a coil wire, the commutator 3 comprises a commutator hook 5 and a commutator sheet 4 for the coil end 6 of the rotor coil 2 as a hook commutator, the coil end 6 In the method of manufacturing a rotor for an electric motor, which is engaged with the hook inner surfaces 7, 8 of each commutator hook 5 by a high temperature caulking method,
Point or line stress is applied through the hook inner surfaces 7, 8 of each commutator hook 5 before and / or during high temperature caulking for damage and / or separation of the insulator of the coil end 6, respectively. A method of manufacturing a rotor for an electric motor, characterized in that it is provided at the coil end (6) of the motor.

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