US20140084745A1 - Commutator - Google Patents
Commutator Download PDFInfo
- Publication number
- US20140084745A1 US20140084745A1 US14/029,611 US201314029611A US2014084745A1 US 20140084745 A1 US20140084745 A1 US 20140084745A1 US 201314029611 A US201314029611 A US 201314029611A US 2014084745 A1 US2014084745 A1 US 2014084745A1
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- United States
- Prior art keywords
- insulator
- commutator
- recess
- segment
- engagement
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K13/00—Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windings; Disposition of current collectors in motors or generators; Arrangements for improving commutation
- H02K13/006—Structural associations of commutators
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R39/00—Rotary current collectors, distributors or interrupters
- H01R39/02—Details for dynamo electric machines
- H01R39/04—Commutators
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K13/00—Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windings; Disposition of current collectors in motors or generators; Arrangements for improving commutation
- H02K13/04—Connections between commutator segments and windings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/06—Manufacture of commutators
- H01R43/08—Manufacture of commutators in which segments are not separated until after assembly
Definitions
- the present invention relates to a commutator.
- a commutator for a DC motor includes a cylindrical insulator fixed to a rotary shaft of an armature, and multiple conductive segments attached to the outer circumferential surface of the insulator. Each segment has a riser connected to an end of a coil wound around a core of the armature. Feeding brushes are in sliding contact with the outer circumferential surfaces of the segments. The feeding brushes feed a direct current to the coil of the armature via the segments.
- the aforementioned commutator is manufactured as follows. A cylindrical conductive material is placed in a die and a plastic material is poured into the cylindrical material, thereby forming the aforementioned insulator. Then, the cylindrical material is cut along the axis to form the aforementioned segments.
- Japanese Laid-Open Patent Publication No. 2002-51506 discloses such a commutator.
- a surface of the segment contacting the insulator is roughened by being dipped in a roughening liquid to become a roughened surface of a structure with tiny recesses and projections.
- This roughened surface increases the area of engagement between the segment and the insulator, compared to the case where the aforementioned surface of the segment is smooth without a structure with recesses and projections, thereby increasing the force of engagement there between.
- the aforementioned segment of the commutator should be subjected to aftertreatment after formation of the roughened surface, such as removal of the roughening liquid existing on the roughened surface.
- the roughened surface is continuously roughened. This changes the structure with recesses and projections for example, leading to reduction of the force of engagement between the segment and the insulator.
- manufacture of the commutator involves a large number of steps.
- a commutator includes a cylindrical insulator and a plurality of commutator pieces formed on an outer circumferential surface of the insulator.
- the commutator pieces are arranged side by side in a circumferential direction of the insulator.
- the commutator pieces are each composed of a conductive plate material.
- the commutator pieces each include a connection claw, which extends outward in a radial direction of the insulator and is configured to be electrically connected to an armature coil, and an engagement claw extending inward in the radial direction of the insulator.
- the engagement claw engages with the insulator.
- the commutator pieces each include a recess portion with an undercut formed in a surface facing inward in the radial direction of the insulator.
- FIG. 1 is a perspective view showing a commutator of a first embodiment
- FIG. 2 is a perspective view showing a segment material of the commutator of FIG. 1 ;
- FIGS. 3A to 3C are cross-sectional views showing a first recess, a second recess, and a third recess respectively formed in the segment of FIG. 2 ;
- FIGS. 4A to 4C are cross-sectional views showing process of forming the first recess of FIG. 3A ;
- FIG. 5 is a perspective view showing the segment material of FIG. 2 ;
- FIG. 6 is a perspective view showing a cylindrical material formed out of the material of FIG. 5 ;
- FIG. 7 is a perspective view showing a condition where risers and inner claws of the cylindrical material of FIG. 6 are bent;
- FIGS. 8A to 8D are cross-sectional views showing process of forming a different recess
- FIGS. 9A to 9C are cross-sectional views showing process of forming a different recess
- FIG. 10 is a perspective view showing a commutator of a second embodiment
- FIG. 11 is a perspective view showing a segment material of the commutator of FIG. 10 ;
- FIG. 12 is a perspective view showing a cutting punch used in manufacture of the commutator of FIG. 10 ;
- FIG. 13 is a perspective view showing a scraping punch used in manufacture of the commutator of FIG. 10 ;
- FIG. 14 is a perspective view showing the segment material of FIG. 11 ;
- FIG. 15 is a perspective view showing a cylindrical material formed out of the material of FIG. 14 ;
- FIG. 16 is a perspective view showing a condition where risers and second inner claws of the cylindrical material of
- FIG. 15 are bent
- FIG. 17A is a perspective view showing the cylindrical material of FIG. 16 in a condition after the cutting punch of FIG. 12 is inserted in the cylindrical material;
- FIG. 17B is a cross-sectional view showing the cylindrical material of FIG. 16 in a condition where the cutting punch of FIG. 12 is placed in the cylindrical material;
- FIG. 18A is a perspective view showing the cylindrical material of FIG. 17A in a condition after the scraping punch of FIG. 13 is inserted in the cylindrical material;
- FIG. 18B is a cross-sectional view showing the cylindrical material of FIG. 17A in a condition where the scraping punch of FIG. 13 is placed in the cylindrical material;
- FIG. 19 is a top view of the cylindrical material of FIG. 17A as seen in the axial direction;
- FIG. 20 is a top view of the cylindrical material of FIG. 18A as seen in the axial direction;
- FIG. 21 is a cross-sectional view of the cylindrical material of FIG. 18A as seen in the axial direction;
- FIGS. 22A to 22C are cross-sectional views showing process of forming a different recess.
- FIGS. 23A to 23D are cross-sectional views showing process of forming a different recess.
- FIGS. 1 to 7 A first embodiment according to the present invention will be described below based on FIGS. 1 to 7 .
- a commutator 10 includes a cylindrical insulator 11 made of a thermosetting plastic, and ten segments 12 (commutator pieces) fixed to the outer circumferential surface of the insulator 11 .
- a press-fitting hole 11 a extending through the insulator 11 in the axial direction is formed at a radial central portion of the insulator 11 .
- a rotary shaft of an armature (not shown) is press-fitted in the press-fitting hole 11 a. Accordingly, the commutator 10 rotates integrally with the rotary shaft of the armature.
- Each segment 12 is formed from a conductive plate material (for example, a metal plate such as a copper plate).
- the ten segments 12 are strips extending in the axial direction of the insulator 11 while being uniformly spaced angularly in the circumferential direction of the insulator 11 .
- a partition groove 13 extending in the axial direction of the insulator 11 is formed between adjacent segments 12 . Specifically, the adjacent segments 12 are spaced from each other by the partition groove 13 . This electrically isolates the ten segments 12 from each other.
- Each partition groove 13 is formed inward in the radial direction to a depth greater than the thickness of each segment 12 (length thereof in the radial direction of the insulator 11 ). The depth of each partition groove 13 in the radial direction is greater than the thickness of each segment 12 .
- Each partition groove 13 is formed to reach the insulator 11 .
- a riser 14 is provided at a first end (upper end of FIG. 1 ) of each segment 12 in the axial direction. At its proximal end, the riser 14 is bent outward in the radial direction of the insulator 11 . The riser 14 faces the radially outer surface of the segment 12 . The riser 14 is connected to an armature coil of an armature (not shown). Specifically, the riser 14 corresponds to a connection claw.
- Two first inner claws 15 are provided at an end of each segment 12 closer to the riser 14 , specifically at the first end.
- the two first inner claws 15 sandwich the riser 14 there between.
- Two second inner claws 16 are provided at a second end of each segment 12 opposite the first end in the axial direction.
- Each of the two second inner claws 16 is arranged at a position to form a pair with the corresponding one of the two first inner claws 15 in the longitudinal direction of the segment 12 .
- the first and second inner claws 15 and 16 are bent toward a side of the radial direction opposite the side of the bending of the riser 14 , specifically they are bent inward in the radial direction of the insulator 11 at their proximal ends.
- first and second inner claws 15 and 16 face the radially inner surface of the segment 12 .
- the distal ends of the first and second inner claws 15 and 16 are buried in the insulator 11 . This couples each segment 12 to the insulator 11 .
- the first and second inner claws 15 and 16 correspond to engagement claws. As shown in FIG. 7 , each of the first and second inner claws 15 and 16 has a cutout 17 formed at a lateral part thereof to open toward the adjacent segment 12 .
- a recess portion 30 is provided in a surface of each segment 12 facing the insulator 11 .
- the recess portion 30 has two recess rows 31 extending in the longitudinal direction of the segment 12 .
- Each recess row 31 includes eight first recesses 32 , five second recesses 33 , and three third recesses 34 .
- the first to third recesses 32 to 34 are arranged in the order from the second end toward the first end of the segment 12 .
- the first to third recesses 32 to 34 are each a triangular recess with an acute angle that is tapered as the distance increases from the surface contacting the insulator 11 .
- the bottom of the triangular recess is defined as the vertex, and a line passing through the vertex and extending toward the riser 14 (second end) in the longitudinal direction of the segment 12 is defined as a reference line (zero-degree direction).
- the first recess 32 is formed to extend over an angular range of from 30 to 80 degrees with respect to the reference line.
- a surface of the first recess 32 at 80 degrees forms an undercut 32 a.
- An undercut shape refers to a shape that makes the opening of a recess project over the bottom of the recess.
- the distance between the bottom of the first recess 32 and the surface contacting the insulator 11 , specifically the depth of the first recess 32 is 30% (0.3t) of a thickness t of the segment 12 .
- the second recess 33 is formed to extend over an angular range of from 100 to 150 degrees with respect to the reference line.
- a surface of the second recess 33 at 100 degrees forms an undercut 33 a.
- the distance between the bottom of the second recess 33 and the surface contacting the insulator 11 is 30% (0.3t) of the thickness t.
- the third recess 34 is formed to extend over an angular range of from 100 to 150 degrees with respect to the reference line.
- a surface of the third recess 34 at 100 degrees forms an undercut 34 a.
- the distance between the bottom of the third recess 34 and the surface contacting the insulator 11 is 50% (0.5t) of the thickness t.
- a wedged punch 9 of an angle of 50 degrees at its distal end is pressed into a metal plate material 20 at an angle of 30 degrees with respect to a plate surface. Then, the punch 9 is pulled out as shown in FIG. 4C . As a result, the first recess 32 is formed.
- the second and third recesses 33 and 34 are formed in a similar way as the first recess 32 , except that the punch 9 is placed at an angle of 150 degrees with respect to the plate surface during the pressing.
- a blank material 21 is punched out of the metal plate material 20 , in which the recess portions 30 are formed.
- the blank material 21 is formed into a substantially rectangular shape.
- Ten risers 14 and twenty first inner claws 15 are formed at one end of each blank material 21 in the transverse direction (perpendicular to the longitudinal direction).
- Twenty second inner claws 16 are formed at the opposite end of each blank material 21 .
- the risers 14 are spaced uniformly in the longitudinal direction of the blank material 21 .
- the first inner claws 15 are formed on both sides of each riser 14 .
- the second inner claws 16 are formed at positions corresponding to the positions of the first inner claws 15 in the longitudinal direction of the blank material 21 .
- the first and second inner claws 15 and 16 have the cutouts 17 .
- the blank material 21 is rolled up such that the recess portions 30 face inward in the radial direction, thereby forming a cylindrical material 22 shown in FIG. 6 .
- the risers 14 , and the first and second inner claws 15 and 16 linearly extend parallel to the axis of the cylindrical material 22 .
- each riser 14 is bent outward in the radial direction such that the distal end of each riser 14 faces a central portion of the cylindrical material 22 in the axial direction.
- the first and second inner claws 15 and 16 are bent inward in the radial direction such that the respective distal ends of the first and second inner claws 15 and 16 face the central portion of the cylindrical material 22 in the axial direction.
- thermosetting plastic is poured into the cylindrical material 22 by using a die (not shown). After the pouring, the plastic is chemically reacted to be cured, thereby forming the insulator 11 shown in FIG. 1 .
- the partition grooves 13 are formed at multiple places of the outer circumferential surface of the cylindrical material 22 integral with the insulator 11 to extend in the axial direction. As a result, the cylindrical material 22 is cut into the ten segments 12 electrically isolated from each other, thereby completing the commutator 10 of FIG. 1 .
- a recess portion 30 is formed in a surface of the segment 12 that contacts the insulator 11 .
- the recess portion 30 is formed by pressing.
- formation of the recess portion 30 involves a small number of steps. Forming the recess portion 30 in the segment 12 increases the area of engagement between the segment 12 and the insulator 11 , compared to the case where the recess portion 30 is not formed. This increases the force of engagement (catching force) between the segment 12 and the insulator 11 .
- the first to third recesses 32 to 34 forming the recess portion 30 have the undercuts 32 a to 34 a, respectively.
- the undercut 32 a is formed on a surface at 80 degrees.
- the undercuts 33 a and 34 a are formed on surfaces at 100 degrees.
- a contact surface between the segment 12 and the insulator 11 at the undercut 32 a is at an angle different from the angle thereof at the undercuts 33 a and 34 a.
- the undercut 32 a tilts in a different direction from the undercuts 33 a and 34 a.
- centrifugal force acting outward in the radial direction of the insulator 11 (90-degree direction) is applied to the segment 12 .
- the segment 12 would be displaced along the undercuts 32 a to 34 a.
- the segment 12 would be displaced toward an end closer to the riser 14 at a contact area with the undercut 32 a, whereas it would be displaced toward an end opposite the end closer to the riser 14 at areas contacting the undercuts 33 a and 34 a.
- all areas of the segment 12 would move in different directions in the longitudinal direction by the presence of the undercuts 32 a to 34 a. Forces on these areas act in different directions, so that these forces cancel each other out. As a result, the force of engagement between the segment 12 and the insulator 11 is increased.
- the depth of the third recess 34 (0.5t) is greater than the depths of the first and second recesses 32 and 33 (0.3t). This makes the segment 12 and the insulator 11 engage each other at the third recess 34 in an amount greater than amounts observed at the first and second recesses 32 and 33 .
- the amount of the plastic of the insulator 11 engaged at the undercut 34 a is greater than the amounts engaged at the undercuts 32 a and 33 a. This relatively increases the force of engagement between the segment 12 and the insulator 11 in the area where the third recess 34 is formed.
- the areas where the first and second recesses 32 and 33 are formed make sliding contact with brushes (not shown) when the commutator 10 rotates.
- the small depths of the first and second recesses 32 and 33 make the segment 12 thick in the areas where these recesses are formed.
- the insulator 11 is not exposed even if these areas are worn to some extent. This allows the commutator 10 to achieve its function over an extended period of time.
- the segment 12 is less likely to come off the insulator 11 than in the case where a recess (third recess 34 ) formed in an area that will not be worn is substantially the same in depth as a recess (first and second recesses 32 and 33 ) formed in an area that will be worn. Additionally, the lifetime of the commutator is extended.
- the first embodiment achieves the following advantages.
- the segment 12 is provided with the recess portion 30 having the undercuts 32 a to 34 a.
- the recess portion 30 is formed by pressing, which can be conducted easily.
- the force of engagement between the segment 12 and the insulator 11 is increased, compared to the case where recesses are not formed.
- the segment 12 is unlikely to come off the insulator 11 .
- the first to third recesses 32 to 34 forming the recess portion 30 have the undercuts 32 a to 34 a, respectively.
- Centrifugal force acting on each segment 12 when the commutator 10 rotates is divided into a component acting in a direction along the undercuts 32 a to 34 a and a component acting in a direction perpendicular to the undercuts 32 a to 34 a.
- only the component acting in the direction along the undercuts 32 a to 34 a acts to separate the segment 12 and the insulator 11 from each other.
- the magnitude of this component is smaller than that of the centrifugal force.
- the segment 12 is less likely to come off the insulator 11 than in the case where the first to third recesses 32 to 34 do not have the undercuts 32 a to 34 a.
- the recess portion 30 is provided between the first inner claws 15 and the second inner claws 16 . This increases the area of engagement between the segment 12 and the insulator 11 at a central portion of the segment 12 in the longitudinal direction, compared to the case where the recess portion 30 is not formed. Thus, the segment 12 is unlikely to come off the insulator 11 .
- the third recess 34 provided in an area of the segment 12 facing the riser 14 in the radial direction is formed to be deeper than the first and second recesses 32 and 33 formed in different areas of the segment 12 .
- the segment 12 is unlikely to come off the insulator 11 .
- the riser 14 is connected to the armature coil, so that the area facing the riser 14 does not make sliding contact with the brushes. Hence, this area is not worn, and therefore the thickness of the area is not reduced.
- the lifetime of the commutator 10 is not shortened even though the third recess 34 in this area is formed deeper than the first and second recesses 32 and 33 formed in different areas.
- the second embodiment mainly differs from the first embodiment in a first inner claw.
- Like or the same reference numerals are given to those components that are like or the same as the corresponding components of the first embodiment, and detailed explanations are omitted.
- a commutator 101 includes a cylindrical insulator 11 , and eighteen segments 120 fixed to the outer circumferential surface of the insulator 11 .
- the eighteen segments 120 are uniformly spaced angularly in the circumferential direction.
- the segments 120 each occupy an angle ⁇ 1 in the circumferential direction.
- the eighteen segments 120 together have an inside diameter ⁇ 1 and an outer diameter ⁇ 2 .
- a surface of each segment 120 facing the insulator 11 has two first inner claws 121 and a recess portion 130 .
- the two first inner claws 121 are arranged closer to the riser 14
- the recess portion 130 is arranged closer to the second inner claws 16 .
- the two first inner claws 121 are arranged side by side in the circumferential direction.
- the two first inner claws 121 are formed by forming cuts in the radially inner surface of the segment 120 , raising the cuts, and bending the cuts at their proximal ends toward the second inner claws 16 . This makes distal ends of the two first inner claws 121 face the radially inner surface of the segment 120 and more precisely, face the recess portion 130 .
- the two first inner claws 121 are buried in the insulator 11 together with distal ends of the two second inner claws 16 . This couples each segment 120 to the insulator 11 . Accordingly, the first inner claws 121 correspond to engagement claws.
- two resultant grooves 122 are formed in the radially inner surface of each segment 120 to extend in the longitudinal direction of the segment 120 .
- the two resultant grooves 122 are arranged side by side in the circumferential direction.
- undercuts 124 are formed on each side wall of an opening 123 of each resultant groove 122 .
- the undercuts 124 project toward each other in the circumferential direction of the insulator 11 .
- the recess portion 130 includes five first recesses 131 and five second recesses 132 .
- the five first recesses 131 are arranged closer to the second inner claws 16 and the five second recesses 132 are arranged closer to the riser 14 .
- the first and second recesses 131 and 132 have the same structures as those of the first and second recesses 32 and 33 of the first embodiment shown in FIGS. 3A to 3C , thus they will not be described in detail.
- a cutting punch 140 and a scraping punch 150 used in manufacture of the commutator 101 will now be described.
- the cutting punch 140 includes a cylindrical portion 141 , and cutting blades 142 in eighteen groups provided on the outer circumferential surface of the cylindrical portion 141 and extending coaxially with the cylindrical portion 141 .
- the cylindrical portion 141 has an outer diameter ⁇ 6 smaller than the inside diameter ⁇ 1 of the segment assembly composed of the eighteen segments 120 ( ⁇ 6 ⁇ 1 ).
- Each group of the cutting blades 142 includes two cutting blades.
- the cutting blades 142 in eighteen groups are arranged side by side and spaced uniformly in an annular pattern. These thirty-six cutting blades 142 form a cutting blade assembly having an outer diameter ⁇ 3 larger than the inside diameter ⁇ 1 of the segment assembly and smaller than the outer diameter ⁇ 2 of the segment assembly ( ⁇ 1 ⁇ 3 ⁇ 2 ).
- An end of the cutting punch 140 that is inserted into a cylindrical material 161 (upper end of FIG. 12 and lower end of FIG. 17B ), which will be described below, has a conical shape with the radially outer edge having sharpened shape.
- part of the cutting punch 140 forming its outer diameter projects in the axial direction relative to the inner diameter portion.
- the facing surfaces of the two cutting blades 142 in each group are separated from each other in the circumferential direction, whereas the surfaces of these blades 142 not facing each other form an angle ⁇ 2 , which is smaller than the angle ⁇ 1 occupied by one segment 120 ( ⁇ 2 ⁇ 1 ).
- the scraping punch 150 includes a columnar scraping portion 151 , a columnar pressing and bending portion 152 coaxial with the scraping portion 151 , and a connecting portion 153 connecting the scraping portion 151 and the pressing and bending portion 152 .
- the scraping portion 151 has a diameter 95 larger than the inside diameter ⁇ 1 of the segment assembly and smaller than the outer diameter ⁇ 3 of the cutting punch 140 (or cutting blade assembly) ( ⁇ 1 ⁇ 5 ⁇ 3 ). Eighteen escape grooves 154 extending in the axial direction are formed in the scraping portion 151 while being uniformly spaced angularly.
- the pressing and bending portion 152 has an outer diameter ⁇ 4 smaller than the inside diameter ⁇ 1 of the segment assembly ( ⁇ 4 ⁇ 1 ).
- the connecting portion 153 is formed into a tapered shape with a gradually decreasing outer diameter toward the pressing and bending portion 152 .
- Steps of manufacturing the commutator 101 using the cutting punch 140 and the scraping punch 150 will now be described. Steps of manufacturing the recess portion 130 is the same as those of manufacturing the recess portion 30 of the first embodiment, thus they will not be described.
- a blank material 160 is punched out of a metal plate material 20 .
- the blank material 160 is formed into a substantially rectangular shape.
- the eighteen risers 14 are formed at one end of each blank material 160 in the transverse direction (perpendicular to the longitudinal direction), whereas the thirty-six second inner claws 16 are formed at the opposite end of each blank material 160 .
- the risers 14 are spaced uniformly in the longitudinal direction of the blank material 160 .
- the second inner claws 16 are formed to sandwich a position that faces each riser 14 there between in the longitudinal direction of the blank material 160 .
- the second inner claws 16 have cutouts 17 .
- the blank material 160 is rolled up such that the recess portion 130 faces inward in the radial direction, thereby forming the cylindrical material 161 shown in FIG. 15 .
- the risers 14 and the second inner claws 16 extend linearly parallel to the axis of the cylindrical material 161 .
- each riser 14 is bent radially outward. Further, the second inner claws 16 are bent inward in the radial direction such that the distal ends of the second inner claws 16 face a central portion of the cylindrical material 22 in the axial direction.
- the cutting punch 140 is inserted into the cylindrical material 161 from an end near the risers 14 .
- the cutting punch 140 is inserted into the cylindrical material 161 such that the two cutting blades 142 in each group sandwich each riser 14 there between as viewed from the center of the cylindrical material 161 .
- the cutting punch 140 forms cuts in the inner surface of the cylindrical material 161 and raises these cuts, thereby forming the thirty-six first inner claws 121 as shown in FIGS. 17A and 17B .
- This forms the thirty-six resultant grooves 122 in the inner surface of the cylindrical material 161 as counterparts of the thirty-six first inner claws 121 .
- the cutting punch 140 forms cuts in the surface and raises these cuts.
- the opposite side walls of the opening 123 of each of the thirty-six resultant groove 122 bulge radially inward from the inner surface of the cylindrical material 161 .
- the cutting punch 140 is removed from the cylindrical material 161 .
- the scraping punch 150 is inserted into the cylindrical material 161 from the end near the risers 14 as shown in FIG. 18B .
- the scraping punch 150 is inserted into the cylindrical material 161 such that the escape grooves 154 (see FIG. 13 ) do not overlap the resultant grooves 122 as viewed from the center of the cylindrical material 161 .
- the outer circumferential surface of the scraping punch 150 does not make sliding motion with the inner circumferential surface of the cylindrical material 161 . Specifically, resistance is not generated against sliding motion resulting from insertion of the scraping punch 150 , so that the scraping punch 150 is easily inserted.
- the outer diameter ⁇ 5 of the scraping portion 151 is larger than the inside diameter ⁇ 1 of the cylindrical material 161 (or segment assembly) and smaller than the outer diameter ⁇ 3 of the cutting blade assembly composed of the cutting blades 142 .
- insertion of the scraping portion 151 folds the opposite side walls of the opening 123 of each resultant groove 122 , specifically the opposite side walls of each opening 123 having projected in response to the cutting and raising by the cutting punch 140 , so that the opening area of this opening 123 is reduced.
- the opposite side walls of the opening 123 facing each other in the circumferential direction are folded to approach each other, thereby forming the undercut 124 .
- thermosetting plastic is poured into the cylindrical material 161 by using a die (not shown). As a result, the thermosetting plastic flows into all the grooves including the resultant grooves 122 as shown in FIG. 21 . After the pouring, the plastic is chemically reacted to be cured, thereby forming the insulator 11 shown in FIG. 10 .
- the partition grooves 13 are formed in multiple places not overlapping the resultant grooves 122 in the outer circumferential surface of the cylindrical material 161 integral with the insulator 11 to extend in the axial direction.
- the cylindrical material 161 is cut into the eighteen segments 120 electrically isolated from each other, thereby completing the commutator 101 of FIG. 10 .
- the undercuts 124 are formed at the openings 123 of the resultant grooves 122 .
- the insulator 11 composed of the cured thermosetting plastic fills the resultant grooves 122 , so that the undercuts 124 achieve the anchor effect. This increases the force of engagement between the segment 120 and the insulator 11 .
- the partition groove 13 does not overlap the resultant groove 122 .
- the openings of the resultant grooves 122 are not continuous with an edge of the segment 120 in the circumferential direction of the insulator 11 . This allows formation of the undercuts 124 at both openings 123 of the resultant grooves 122 arranged in the circumferential direction of the insulator 11 . As a result, force of engagement between the segment 120 and the insulator 11 is increased.
- the second embodiment achieves the following advantages in addition to the advantages of the first embodiment.
- the first inner claws 121 are formed by forming cuts in an inner surface of the segment 120 facing the insulator 11 and raising the cuts.
- the undercuts 124 are formed at the openings 123 of the resultant grooves 122 resulting from forming and raising the cuts in the surface facing the insulator 11 .
- the insulator 11 composed of the cured thermosetting plastic fills the resultant grooves 122 . This achieves anchor effect, so that the force of engagement between the segment 120 and the insulator 11 is increased.
- the partition groove 13 does not overlap the resultant groove 122 .
- the openings of the resultant grooves 122 are not continuous with an edge of the segment 120 in the circumferential direction of the insulator 11 .
- This allows formation of the undercuts 124 at both openings 123 of the resultant grooves 122 arranged in the circumferential direction of the insulator 11 .
- force of engagement between the segment 120 and the insulator 11 is increased, compared to the case where an undercut cannot be formed at at least one of these openings.
- an undercut may be formed as follows. As shown in FIG. 8A , the wedged punch 9 is pressed into the metal plate material 20 at an angle of 40 degrees with respect to a plate surface. Then, the wedged punch 9 is pulled out of the metal plate material 20 . As a result, a recess 80 is formed and the plate surface projects in an area surrounding the recess 80 as shown in FIG. 8B . Next, as shown in FIG. 8C , a dice-shaped punch 85 greater in width than the recess 80 is pressed into the metal plate material 20 in the direction of the thickness of the metal plate material 20 . This folds the projecting area surrounding the recess 80 , and the folded area forms an undercut 81 as shown in FIG. 8D .
- An undercut may also be formed as follows. As shown in
- FIG. 9A a wedged punch 95 is pressed into the metal plate material 20 at a right angle (90 degrees) with respect to a plate surface. Then, the wedged punch 95 is pulled out of the metal plate material 20 . As a result, a recess 90 with a vertical surface 92 is formed as shown in FIG. 9B . Next, as shown in FIG. 9C , the punch 95 is pressed into an area near the vertical surface 92 of the resultant recess 90 . This folds the vertical surface 92 of the recess 90 , and the area that has been the vertical surface 92 forms an undercut 91 . An undercut formed by the steps shown in FIGS. 8A to 8D and FIGS. 9A to 9D achieves the same advantages as those of the aforementioned embodiments.
- An undercut may also be formed as follows. As shown in FIG. 22A , recesses 90 in a pair are formed with the aforementioned wedged punch 95 such that vertical surfaces 92 in a pair are arranged close to each other. Next, as shown in FIG. 22B , a wedged punch 96 of a different shape is pressed into between the recesses 90 in a pair, specifically between the vertical surfaces 92 in a pair.
- the wedged punch 96 has a shape that is tapered from its proximal end toward its distal end, which is configured to be pressed into the metal plate material 20 .
- An undercut may also be formed with a punch 180 as follows. As shown in FIG. 23A , the punch 180 has a first processing surface 181 , a second processing surface 182 continuous with the first processing surface 181 , and a third processing surface 183 continuous with the second processing surface 182 . A vertex between the second and third processing surfaces 182 and 183 is defined as a processing tip 184 . The punch 180 as a whole is tapered toward the processing tip 184 .
- the processing tip 184 of the punch 180 is pressed into the metal plate material 20 such that the first processing surface 181 becomes at a right angle with respect to a plate surface of the metal plate material 20 .
- the recess 190 has a first processed surface 191 corresponding to the first processing surface 181 , a second processed surface 192 corresponding to the second processing surface 182 , and a third processed surface 193 corresponding to the third processing surface 183 .
- the first processed surface 191 is at a right angle with respect to the plate surface.
- the recess 190 further has a first processed ridge 194 formed between the first and second processed surfaces 191 and 192 , and a second processed ridge 195 formed between the second and third processed surfaces 192 and 193 .
- the punch 95 is pressed into an area near the first processed surface 191 of the resultant recess 190 . At this time, the punch 95 is pressed such that the distance between the tip of the punch 95 and the plate surface of the metal plate material 20 becomes the same as the distance between the first processed ridge 194 and the plate surface of the metal plate material 20 .
- This process can be conducted easily since it uses a smaller amount of the plate material to be folded from a vertical state, compared to the case where an undercut is formed by the steps shown in FIGS. 8A to 8C .
- the recess portion 30 has two recess rows 31 .
- the recess portion 30 may also have only one recess row as in the second embodiment or may have three or more recess rows. These achieve the same advantages as those of the first embodiment.
- the third recess 34 is deeper than the first and second recesses 32 and 33 in the first embodiment.
- the third recess 34 may be the same in depth as the first and second recesses 32 and 33 . This achieves the same advantages as the advantages (1) to (4) of the first embodiment.
- the undercuts 32 a to 34 a may tilt in the same direction. This achieves the same advantages as the advantages (1) to (3) and (5) of the first embodiment. Further, in the second embodiment, undercuts formed at the recess portion 130 may tilt in the same direction.
- recess portions 30 and 130 each include multiple recesses in the first and second embodiments, they may each include one or more recesses.
- first inner claws 15 and two second inner claws 16 are formed in the first embodiment, only one first inner claw 15 and only one second inner claw 16 may be formed.
- the first and second inner claws 15 and 16 are not always required to form a pair in the longitudinal direction of the segment 12 .
- One the first and second inner claws 15 , 16 may be omitted.
- only one first inner claw 121 , or three or more first inner claws 121 may be formed.
- each of the first to third recesses 32 and 34 in the first embodiment may also be formed at at least one of the first to third recesses 32 to 34 .
- the number of the segments 12 is ten and eighteen, respectively.
- the number of the segments 12 is not limited to these numbers and it may be changed as necessary depending on a structure.
- the cylindrical material 22 is formed by rolling up the blank material 21 punched out of the metal plate material 20 and then the segments 12 are formed by cutting the cylindrical material 22 .
- the segments 12 may be punched directly out of the metal plate material 20 .
- the escape grooves 154 may be omitted from the scraping punch 150 .
Abstract
A commutator includes a cylindrical insulator and commutator pieces, which are formed on the outer circumferential surface of the insulator and arranged side by side in the circumferential direction of the insulator. The commutator pieces are each composed of a conductive plate material, and each includes a connection claw and an engagement claw. The connection claw extends outward in the radial direction of the insulator while being configured to electrically being connected to an armature coil. The engagement claw extends inward in the radial direction of the insulator and engages with the insulator. The commutator pieces each include a recess portion with an undercut formed in a surface facing inward in the radial direction of the insulator.
Description
- The present invention relates to a commutator.
- A commutator for a DC motor includes a cylindrical insulator fixed to a rotary shaft of an armature, and multiple conductive segments attached to the outer circumferential surface of the insulator. Each segment has a riser connected to an end of a coil wound around a core of the armature. Feeding brushes are in sliding contact with the outer circumferential surfaces of the segments. The feeding brushes feed a direct current to the coil of the armature via the segments.
- The aforementioned commutator is manufactured as follows. A cylindrical conductive material is placed in a die and a plastic material is poured into the cylindrical material, thereby forming the aforementioned insulator. Then, the cylindrical material is cut along the axis to form the aforementioned segments.
- Japanese Laid-Open Patent Publication No. 2002-51506 discloses such a commutator. According to Japanese Laid-Open Patent Publication No. 2002-51506, in order to ensure force of engagement between the insulator and each segment, a surface of the segment contacting the insulator is roughened by being dipped in a roughening liquid to become a roughened surface of a structure with tiny recesses and projections. This roughened surface increases the area of engagement between the segment and the insulator, compared to the case where the aforementioned surface of the segment is smooth without a structure with recesses and projections, thereby increasing the force of engagement there between.
- The aforementioned segment of the commutator should be subjected to aftertreatment after formation of the roughened surface, such as removal of the roughening liquid existing on the roughened surface. In the absence of this aftertreatment, the roughened surface is continuously roughened. This changes the structure with recesses and projections for example, leading to reduction of the force of engagement between the segment and the insulator. Hence, manufacture of the commutator involves a large number of steps.
- It is an objective of the present invention to provide a commutator that provides a high engagement force between segments and an insulator and requires a small number of manufacturing of steps.
- To achieve the foregoing objective and in accordance with one aspect of the present invention, a commutator is provided. The commutator includes a cylindrical insulator and a plurality of commutator pieces formed on an outer circumferential surface of the insulator. The commutator pieces are arranged side by side in a circumferential direction of the insulator. The commutator pieces are each composed of a conductive plate material. The commutator pieces each include a connection claw, which extends outward in a radial direction of the insulator and is configured to be electrically connected to an armature coil, and an engagement claw extending inward in the radial direction of the insulator. The engagement claw engages with the insulator. The commutator pieces each include a recess portion with an undercut formed in a surface facing inward in the radial direction of the insulator.
- The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
-
FIG. 1 is a perspective view showing a commutator of a first embodiment; -
FIG. 2 is a perspective view showing a segment material of the commutator ofFIG. 1 ; -
FIGS. 3A to 3C are cross-sectional views showing a first recess, a second recess, and a third recess respectively formed in the segment ofFIG. 2 ; -
FIGS. 4A to 4C are cross-sectional views showing process of forming the first recess ofFIG. 3A ; -
FIG. 5 is a perspective view showing the segment material ofFIG. 2 ; -
FIG. 6 is a perspective view showing a cylindrical material formed out of the material ofFIG. 5 ; -
FIG. 7 is a perspective view showing a condition where risers and inner claws of the cylindrical material ofFIG. 6 are bent; -
FIGS. 8A to 8D are cross-sectional views showing process of forming a different recess; -
FIGS. 9A to 9C are cross-sectional views showing process of forming a different recess; -
FIG. 10 is a perspective view showing a commutator of a second embodiment; -
FIG. 11 is a perspective view showing a segment material of the commutator ofFIG. 10 ; -
FIG. 12 is a perspective view showing a cutting punch used in manufacture of the commutator ofFIG. 10 ; -
FIG. 13 is a perspective view showing a scraping punch used in manufacture of the commutator ofFIG. 10 ; -
FIG. 14 is a perspective view showing the segment material ofFIG. 11 ; -
FIG. 15 is a perspective view showing a cylindrical material formed out of the material ofFIG. 14 ; -
FIG. 16 is a perspective view showing a condition where risers and second inner claws of the cylindrical material of -
FIG. 15 are bent; -
FIG. 17A is a perspective view showing the cylindrical material ofFIG. 16 in a condition after the cutting punch ofFIG. 12 is inserted in the cylindrical material; -
FIG. 17B is a cross-sectional view showing the cylindrical material ofFIG. 16 in a condition where the cutting punch ofFIG. 12 is placed in the cylindrical material; -
FIG. 18A is a perspective view showing the cylindrical material ofFIG. 17A in a condition after the scraping punch ofFIG. 13 is inserted in the cylindrical material; -
FIG. 18B is a cross-sectional view showing the cylindrical material ofFIG. 17A in a condition where the scraping punch ofFIG. 13 is placed in the cylindrical material; -
FIG. 19 is a top view of the cylindrical material ofFIG. 17A as seen in the axial direction; -
FIG. 20 is a top view of the cylindrical material ofFIG. 18A as seen in the axial direction; -
FIG. 21 is a cross-sectional view of the cylindrical material ofFIG. 18A as seen in the axial direction; -
FIGS. 22A to 22C are cross-sectional views showing process of forming a different recess; and -
FIGS. 23A to 23D are cross-sectional views showing process of forming a different recess. - A first embodiment according to the present invention will be described below based on
FIGS. 1 to 7 . - As shown in
FIG. 1 , acommutator 10 includes acylindrical insulator 11 made of a thermosetting plastic, and ten segments 12 (commutator pieces) fixed to the outer circumferential surface of theinsulator 11. A press-fittinghole 11 a extending through theinsulator 11 in the axial direction is formed at a radial central portion of theinsulator 11. A rotary shaft of an armature (not shown) is press-fitted in the press-fittinghole 11 a. Accordingly, thecommutator 10 rotates integrally with the rotary shaft of the armature. - Each
segment 12 is formed from a conductive plate material (for example, a metal plate such as a copper plate). The tensegments 12 are strips extending in the axial direction of theinsulator 11 while being uniformly spaced angularly in the circumferential direction of theinsulator 11. Apartition groove 13 extending in the axial direction of theinsulator 11 is formed betweenadjacent segments 12. Specifically, theadjacent segments 12 are spaced from each other by thepartition groove 13. This electrically isolates the tensegments 12 from each other. Eachpartition groove 13 is formed inward in the radial direction to a depth greater than the thickness of each segment 12 (length thereof in the radial direction of the insulator 11). The depth of eachpartition groove 13 in the radial direction is greater than the thickness of eachsegment 12. Eachpartition groove 13 is formed to reach theinsulator 11. - A
riser 14 is provided at a first end (upper end ofFIG. 1 ) of eachsegment 12 in the axial direction. At its proximal end, theriser 14 is bent outward in the radial direction of theinsulator 11. Theriser 14 faces the radially outer surface of thesegment 12. Theriser 14 is connected to an armature coil of an armature (not shown). Specifically, theriser 14 corresponds to a connection claw. - Two first
inner claws 15 are provided at an end of eachsegment 12 closer to theriser 14, specifically at the first end. The two firstinner claws 15 sandwich theriser 14 there between. Two secondinner claws 16 are provided at a second end of eachsegment 12 opposite the first end in the axial direction. Each of the two secondinner claws 16 is arranged at a position to form a pair with the corresponding one of the two firstinner claws 15 in the longitudinal direction of thesegment 12. The first and secondinner claws riser 14, specifically they are bent inward in the radial direction of theinsulator 11 at their proximal ends. The distal ends of the first and secondinner claws segment 12. The distal ends of the first and secondinner claws insulator 11. This couples eachsegment 12 to theinsulator 11. The first and secondinner claws FIG. 7 , each of the first and secondinner claws cutout 17 formed at a lateral part thereof to open toward theadjacent segment 12. - As shown in
FIG. 2 , arecess portion 30 is provided in a surface of eachsegment 12 facing theinsulator 11. Therecess portion 30 has two recess rows 31 extending in the longitudinal direction of thesegment 12. Each recess row 31 includes eightfirst recesses 32, fivesecond recesses 33, and threethird recesses 34. The first tothird recesses 32 to 34 are arranged in the order from the second end toward the first end of thesegment 12. As shown inFIGS. 3A to 3C , the first tothird recesses 32 to 34 are each a triangular recess with an acute angle that is tapered as the distance increases from the surface contacting theinsulator 11. - As shown in
FIG. 3A , the bottom of the triangular recess is defined as the vertex, and a line passing through the vertex and extending toward the riser 14 (second end) in the longitudinal direction of thesegment 12 is defined as a reference line (zero-degree direction). Thefirst recess 32 is formed to extend over an angular range of from 30 to 80 degrees with respect to the reference line. A surface of thefirst recess 32 at 80 degrees forms an undercut 32 a. An undercut shape refers to a shape that makes the opening of a recess project over the bottom of the recess. The distance between the bottom of thefirst recess 32 and the surface contacting theinsulator 11, specifically the depth of thefirst recess 32 is 30% (0.3t) of a thickness t of thesegment 12. - As shown in
FIG. 3B , thesecond recess 33 is formed to extend over an angular range of from 100 to 150 degrees with respect to the reference line. A surface of thesecond recess 33 at 100 degrees forms an undercut 33 a. The distance between the bottom of thesecond recess 33 and the surface contacting theinsulator 11 is 30% (0.3t) of the thickness t. - As shown in
FIG. 3C , thethird recess 34 is formed to extend over an angular range of from 100 to 150 degrees with respect to the reference line. A surface of thethird recess 34 at 100 degrees forms an undercut 34 a. The distance between the bottom of thethird recess 34 and the surface contacting theinsulator 11 is 50% (0.5t) of the thickness t. - Steps of manufacturing the
commutator 10 will now be described. - As shown in
FIGS. 4A and 4B , a wedgedpunch 9 of an angle of 50 degrees at its distal end is pressed into ametal plate material 20 at an angle of 30 degrees with respect to a plate surface. Then, thepunch 9 is pulled out as shown inFIG. 4C . As a result, thefirst recess 32 is formed. Although not illustrated, the second andthird recesses first recess 32, except that thepunch 9 is placed at an angle of 150 degrees with respect to the plate surface during the pressing. These steps are repeated to form therecess portion 30 in themetal plate material 20, as shown inFIG. 5 . - Next, as shown in
FIG. 5 , ablank material 21 is punched out of themetal plate material 20, in which therecess portions 30 are formed. Theblank material 21 is formed into a substantially rectangular shape. Tenrisers 14 and twenty firstinner claws 15 are formed at one end of eachblank material 21 in the transverse direction (perpendicular to the longitudinal direction). Twenty secondinner claws 16 are formed at the opposite end of eachblank material 21. Therisers 14 are spaced uniformly in the longitudinal direction of theblank material 21. The firstinner claws 15 are formed on both sides of eachriser 14. The secondinner claws 16 are formed at positions corresponding to the positions of the firstinner claws 15 in the longitudinal direction of theblank material 21. The first and secondinner claws cutouts 17. - Next, the
blank material 21 is rolled up such that therecess portions 30 face inward in the radial direction, thereby forming acylindrical material 22 shown inFIG. 6 . At this stage, therisers 14, and the first and secondinner claws cylindrical material 22. - Then, as shown in
FIG. 7 , eachriser 14 is bent outward in the radial direction such that the distal end of eachriser 14 faces a central portion of thecylindrical material 22 in the axial direction. Further, the first and secondinner claws inner claws cylindrical material 22 in the axial direction. - Next, a thermosetting plastic is poured into the
cylindrical material 22 by using a die (not shown). After the pouring, the plastic is chemically reacted to be cured, thereby forming theinsulator 11 shown inFIG. 1 . - Next, the partition grooves 13 (see
FIG. 1 ) are formed at multiple places of the outer circumferential surface of thecylindrical material 22 integral with theinsulator 11 to extend in the axial direction. As a result, thecylindrical material 22 is cut into the tensegments 12 electrically isolated from each other, thereby completing thecommutator 10 ofFIG. 1 . - Operation of the
commutator 10 will now be described. - As shown in
FIG. 2 , arecess portion 30 is formed in a surface of thesegment 12 that contacts theinsulator 11. As shown inFIGS. 4A to 4C , therecess portion 30 is formed by pressing. Thus, formation of therecess portion 30 involves a small number of steps. Forming therecess portion 30 in thesegment 12 increases the area of engagement between thesegment 12 and theinsulator 11, compared to the case where therecess portion 30 is not formed. This increases the force of engagement (catching force) between thesegment 12 and theinsulator 11. - As shown in
FIGS. 3A to 3C , the first tothird recesses 32 to 34 forming therecess portion 30 have theundercuts 32 a to 34 a, respectively. The undercut 32 a is formed on a surface at 80 degrees. The undercuts 33 a and 34 a are formed on surfaces at 100 degrees. Thus, a contact surface between thesegment 12 and theinsulator 11 at the undercut 32 a is at an angle different from the angle thereof at theundercuts undercuts commutator 10 rotates, centrifugal force acting outward in the radial direction of the insulator 11 (90-degree direction) is applied to thesegment 12. If it came off theinsulator 11, thesegment 12 would be displaced along theundercuts 32 a to 34 a. Specifically, thesegment 12 would be displaced toward an end closer to theriser 14 at a contact area with the undercut 32 a, whereas it would be displaced toward an end opposite the end closer to theriser 14 at areas contacting theundercuts segment 12, all areas of thesegment 12 would move in different directions in the longitudinal direction by the presence of theundercuts 32 a to 34 a. Forces on these areas act in different directions, so that these forces cancel each other out. As a result, the force of engagement between thesegment 12 and theinsulator 11 is increased. - Further, as shown in
FIGS. 3A to 3C , the depth of the third recess 34 (0.5t) is greater than the depths of the first andsecond recesses 32 and 33 (0.3t). This makes thesegment 12 and theinsulator 11 engage each other at thethird recess 34 in an amount greater than amounts observed at the first andsecond recesses insulator 11 engaged at the undercut 34 a is greater than the amounts engaged at theundercuts segment 12 and theinsulator 11 in the area where thethird recess 34 is formed. Meanwhile, the areas where the first andsecond recesses commutator 10 rotates. The small depths of the first andsecond recesses segment 12 thick in the areas where these recesses are formed. Thus, theinsulator 11 is not exposed even if these areas are worn to some extent. This allows thecommutator 10 to achieve its function over an extended period of time. As described above, in thecommutator 10 of the present embodiment, thesegment 12 is less likely to come off theinsulator 11 than in the case where a recess (third recess 34) formed in an area that will not be worn is substantially the same in depth as a recess (first andsecond recesses 32 and 33) formed in an area that will be worn. Additionally, the lifetime of the commutator is extended. - As described in detail above, the first embodiment achieves the following advantages.
- (1) The
segment 12 is provided with therecess portion 30 having theundercuts 32 a to 34 a. Therecess portion 30 is formed by pressing, which can be conducted easily. Thus, the force of engagement between thesegment 12 and theinsulator 11 is increased, compared to the case where recesses are not formed. As a result, even if thecommutator 10 rotates at high speed, thesegment 12 is unlikely to come off theinsulator 11. - (2) The first to
third recesses 32 to 34 forming therecess portion 30 have theundercuts 32 a to 34 a, respectively. Centrifugal force acting on eachsegment 12 when thecommutator 10 rotates is divided into a component acting in a direction along theundercuts 32 a to 34 a and a component acting in a direction perpendicular to theundercuts 32 a to 34 a. Of these components, only the component acting in the direction along theundercuts 32 a to 34 a acts to separate thesegment 12 and theinsulator 11 from each other. The magnitude of this component is smaller than that of the centrifugal force. Thus, thesegment 12 is less likely to come off theinsulator 11 than in the case where the first tothird recesses 32 to 34 do not have theundercuts 32 a to 34 a. - (3) The
recess portion 30 is provided between the firstinner claws 15 and the secondinner claws 16. This increases the area of engagement between thesegment 12 and theinsulator 11 at a central portion of thesegment 12 in the longitudinal direction, compared to the case where therecess portion 30 is not formed. Thus, thesegment 12 is unlikely to come off theinsulator 11. - (4) The undercut 32 a tilts in a different direction from the
undercuts commutator 10 rotates, thesegment 12 would be displaced in the direction of the tilt of the undercut 32 a at the area contacting the undercut 32 a, whereas it would be displaced in the direction of the tilts of theundercuts undercuts segment 12 in different directions cancel each other out. As a result, the force of engagement between thesegment 12 and theinsulator 11 is increased, so that thesegment 12 is unlikely to come off theinsulator 11. - (5) The
third recess 34 provided in an area of thesegment 12 facing theriser 14 in the radial direction is formed to be deeper than the first andsecond recesses segment 12. This increases the area of engagement between thesegment 12 and theinsulator 11, compared to the case where all these recesses are formed to the same depth. As a result, thesegment 12 is unlikely to come off theinsulator 11. Theriser 14 is connected to the armature coil, so that the area facing theriser 14 does not make sliding contact with the brushes. Hence, this area is not worn, and therefore the thickness of the area is not reduced. As a result, the lifetime of thecommutator 10 is not shortened even though thethird recess 34 in this area is formed deeper than the first andsecond recesses - A second embodiment of the commutator will now be described. The second embodiment mainly differs from the first embodiment in a first inner claw. Like or the same reference numerals are given to those components that are like or the same as the corresponding components of the first embodiment, and detailed explanations are omitted.
- As shown in
FIG. 10 , acommutator 101 includes acylindrical insulator 11, and eighteensegments 120 fixed to the outer circumferential surface of theinsulator 11. The eighteensegments 120 are uniformly spaced angularly in the circumferential direction. Thesegments 120 each occupy an angle θ1 in the circumferential direction. Except forrisers 14, secondinner claws 16, and firstinner claws 121, which will be described below, the eighteensegments 120 together have an inside diameter φ1 and an outer diameter φ2. Specifically, parts of the eighteensegments 120 excluding theirrisers 14, the secondinner claws 16, and the firstinner claws 121, which will be described below, form a segment assembly having the inside diameter φ1 and the outer diameter φ2. - As shown in
FIG. 11 , a surface of eachsegment 120 facing theinsulator 11 has two firstinner claws 121 and arecess portion 130. In the longitudinal direction of thesegment 120, the two firstinner claws 121 are arranged closer to theriser 14, and therecess portion 130 is arranged closer to the secondinner claws 16. The two firstinner claws 121 are arranged side by side in the circumferential direction. - The two first
inner claws 121 are formed by forming cuts in the radially inner surface of thesegment 120, raising the cuts, and bending the cuts at their proximal ends toward the secondinner claws 16. This makes distal ends of the two firstinner claws 121 face the radially inner surface of thesegment 120 and more precisely, face therecess portion 130. - Thus, the two first
inner claws 121 are buried in theinsulator 11 together with distal ends of the two secondinner claws 16. This couples eachsegment 120 to theinsulator 11. Accordingly, the firstinner claws 121 correspond to engagement claws. - As a result of formation of the two first
inner claws 121, tworesultant grooves 122 are formed in the radially inner surface of eachsegment 120 to extend in the longitudinal direction of thesegment 120. The tworesultant grooves 122 are arranged side by side in the circumferential direction. - As shown in
FIGS. 20 and 21 , undercuts 124 are formed on each side wall of anopening 123 of eachresultant groove 122. Theundercuts 124 project toward each other in the circumferential direction of theinsulator 11. - As shown in
FIG. 11 , therecess portion 130 includes fivefirst recesses 131 and fivesecond recesses 132. The fivefirst recesses 131 are arranged closer to the secondinner claws 16 and the fivesecond recesses 132 are arranged closer to theriser 14. The first andsecond recesses second recesses FIGS. 3A to 3C , thus they will not be described in detail. - A cutting
punch 140 and ascraping punch 150 used in manufacture of thecommutator 101 will now be described. - As shown in
FIG. 12 , the cuttingpunch 140 includes acylindrical portion 141, and cuttingblades 142 in eighteen groups provided on the outer circumferential surface of thecylindrical portion 141 and extending coaxially with thecylindrical portion 141. - The
cylindrical portion 141 has an outer diameter φ6 smaller than the inside diameter φ1 of the segment assembly composed of the eighteen segments 120 (φ6<φ1). - Each group of the
cutting blades 142 includes two cutting blades. Thecutting blades 142 in eighteen groups are arranged side by side and spaced uniformly in an annular pattern. These thirty-sixcutting blades 142 form a cutting blade assembly having an outer diameter φ3 larger than the inside diameter φ1 of the segment assembly and smaller than the outer diameter φ2 of the segment assembly (φ1<φ3<φ2). - An end of the cutting
punch 140 that is inserted into a cylindrical material 161 (upper end ofFIG. 12 and lower end ofFIG. 17B ), which will be described below, has a conical shape with the radially outer edge having sharpened shape. In other words, part of the cuttingpunch 140 forming its outer diameter projects in the axial direction relative to the inner diameter portion. - The facing surfaces of the two cutting
blades 142 in each group are separated from each other in the circumferential direction, whereas the surfaces of theseblades 142 not facing each other form an angle φ2, which is smaller than the angle φ1 occupied by one segment 120 (θ2<θ1). - As shown in
FIG. 13 , the scrapingpunch 150 includes acolumnar scraping portion 151, a columnar pressing and bendingportion 152 coaxial with the scrapingportion 151, and a connectingportion 153 connecting the scrapingportion 151 and the pressing and bendingportion 152. - The scraping
portion 151 has adiameter 95 larger than the inside diameter φ1 of the segment assembly and smaller than the outer diameter φ3 of the cutting punch 140 (or cutting blade assembly) (φ1<φ5<φ3). Eighteenescape grooves 154 extending in the axial direction are formed in the scrapingportion 151 while being uniformly spaced angularly. - The pressing and bending
portion 152 has an outer diameter φ4 smaller than the inside diameter φ1 of the segment assembly (φ4<φ1). - To smoothly connect the outer surface of the scraping
portion 151 to the outer surface of the pressing and bendingportion 152, the connectingportion 153 is formed into a tapered shape with a gradually decreasing outer diameter toward the pressing and bendingportion 152. - Steps of manufacturing the
commutator 101 using the cuttingpunch 140 and thescraping punch 150 will now be described. Steps of manufacturing therecess portion 130 is the same as those of manufacturing therecess portion 30 of the first embodiment, thus they will not be described. - As shown in
FIG. 14 , ablank material 160 is punched out of ametal plate material 20. Theblank material 160 is formed into a substantially rectangular shape. The eighteenrisers 14 are formed at one end of eachblank material 160 in the transverse direction (perpendicular to the longitudinal direction), whereas the thirty-six secondinner claws 16 are formed at the opposite end of eachblank material 160. - The
risers 14 are spaced uniformly in the longitudinal direction of theblank material 160. The secondinner claws 16 are formed to sandwich a position that faces eachriser 14 there between in the longitudinal direction of theblank material 160. The secondinner claws 16 havecutouts 17. - Next, the
blank material 160 is rolled up such that therecess portion 130 faces inward in the radial direction, thereby forming thecylindrical material 161 shown inFIG. 15 . Therisers 14 and the secondinner claws 16 extend linearly parallel to the axis of thecylindrical material 161. - Next, as shown in
FIG. 16 , eachriser 14 is bent radially outward. Further, the secondinner claws 16 are bent inward in the radial direction such that the distal ends of the secondinner claws 16 face a central portion of thecylindrical material 22 in the axial direction. - Next, as shown in
FIG. 17B , the cuttingpunch 140 is inserted into thecylindrical material 161 from an end near therisers 14. The cuttingpunch 140 is inserted into thecylindrical material 161 such that the two cuttingblades 142 in each group sandwich eachriser 14 there between as viewed from the center of thecylindrical material 161. - Then, the cutting
punch 140 forms cuts in the inner surface of thecylindrical material 161 and raises these cuts, thereby forming the thirty-six firstinner claws 121 as shown inFIGS. 17A and 17B . This forms the thirty-sixresultant grooves 122 in the inner surface of thecylindrical material 161 as counterparts of the thirty-six firstinner claws 121. The cuttingpunch 140 forms cuts in the surface and raises these cuts. Thus, as shown inFIG. 19 , the opposite side walls of theopening 123 of each of the thirty-sixresultant groove 122 bulge radially inward from the inner surface of thecylindrical material 161. - Next, the cutting
punch 140 is removed from thecylindrical material 161. Then, the scrapingpunch 150 is inserted into thecylindrical material 161 from the end near therisers 14 as shown inFIG. 18B . The scrapingpunch 150 is inserted into thecylindrical material 161 such that the escape grooves 154 (seeFIG. 13 ) do not overlap theresultant grooves 122 as viewed from the center of thecylindrical material 161. In theescape grooves 154, the outer circumferential surface of thescraping punch 150 does not make sliding motion with the inner circumferential surface of thecylindrical material 161. Specifically, resistance is not generated against sliding motion resulting from insertion of thescraping punch 150, so that thescraping punch 150 is easily inserted. - Then, the pressing and bending
portion 152 and the connectingportion 153 press the firstinner claws 121 to bend the firstinner claws 121 radially inward, as shown inFIGS. 18A and 18B . The outer diameter φ5 of the scrapingportion 151 is larger than the inside diameter φ1 of the cylindrical material 161 (or segment assembly) and smaller than the outer diameter φ3 of the cutting blade assembly composed of thecutting blades 142. Thus, as shown inFIG. 20 , insertion of the scrapingportion 151 folds the opposite side walls of theopening 123 of eachresultant groove 122, specifically the opposite side walls of eachopening 123 having projected in response to the cutting and raising by the cuttingpunch 140, so that the opening area of thisopening 123 is reduced. Specifically, the opposite side walls of theopening 123 facing each other in the circumferential direction are folded to approach each other, thereby forming the undercut 124. - Next, the scraping
punch 150 is removed. Then, a thermosetting plastic is poured into thecylindrical material 161 by using a die (not shown). As a result, the thermosetting plastic flows into all the grooves including theresultant grooves 122 as shown inFIG. 21 . After the pouring, the plastic is chemically reacted to be cured, thereby forming theinsulator 11 shown inFIG. 10 . - Next, the partition grooves 13 (see
FIG. 10 ) are formed in multiple places not overlapping theresultant grooves 122 in the outer circumferential surface of thecylindrical material 161 integral with theinsulator 11 to extend in the axial direction. As a result, thecylindrical material 161 is cut into the eighteensegments 120 electrically isolated from each other, thereby completing thecommutator 101 ofFIG. 10 . - Operation of the
commutator 101 will now be described. - As shown in
FIGS. 20 and 21 , theundercuts 124 are formed at theopenings 123 of theresultant grooves 122. Theinsulator 11 composed of the cured thermosetting plastic fills theresultant grooves 122, so that theundercuts 124 achieve the anchor effect. This increases the force of engagement between thesegment 120 and theinsulator 11. - In each
segment 120 formed by cutting thecylindrical material 161, thepartition groove 13 does not overlap theresultant groove 122. Thus, as shown inFIG. 21 , the openings of theresultant grooves 122 are not continuous with an edge of thesegment 120 in the circumferential direction of theinsulator 11. This allows formation of theundercuts 124 at bothopenings 123 of theresultant grooves 122 arranged in the circumferential direction of theinsulator 11. As a result, force of engagement between thesegment 120 and theinsulator 11 is increased. - As described in detail above, the second embodiment achieves the following advantages in addition to the advantages of the first embodiment.
- (6) The first
inner claws 121 are formed by forming cuts in an inner surface of thesegment 120 facing theinsulator 11 and raising the cuts. Theundercuts 124 are formed at theopenings 123 of theresultant grooves 122 resulting from forming and raising the cuts in the surface facing theinsulator 11. Theinsulator 11 composed of the cured thermosetting plastic fills theresultant grooves 122. This achieves anchor effect, so that the force of engagement between thesegment 120 and theinsulator 11 is increased. - (7) In each
segment 120 formed by cutting thecylindrical material 161, thepartition groove 13 does not overlap theresultant groove 122. Thus, the openings of theresultant grooves 122 are not continuous with an edge of thesegment 120 in the circumferential direction of theinsulator 11. This allows formation of theundercuts 124 at bothopenings 123 of theresultant grooves 122 arranged in the circumferential direction of theinsulator 11. As a result, force of engagement between thesegment 120 and theinsulator 11 is increased, compared to the case where an undercut cannot be formed at at least one of these openings. - Each of the aforementioned embodiments may be modified as follows.
- In the first and second embodiments, an undercut may be formed as follows. As shown in
FIG. 8A , the wedgedpunch 9 is pressed into themetal plate material 20 at an angle of 40 degrees with respect to a plate surface. Then, the wedgedpunch 9 is pulled out of themetal plate material 20. As a result, arecess 80 is formed and the plate surface projects in an area surrounding therecess 80 as shown inFIG. 8B . Next, as shown inFIG. 8C , a dice-shapedpunch 85 greater in width than therecess 80 is pressed into themetal plate material 20 in the direction of the thickness of themetal plate material 20. This folds the projecting area surrounding therecess 80, and the folded area forms an undercut 81 as shown inFIG. 8D . - An undercut may also be formed as follows. As shown in
-
FIG. 9A , a wedgedpunch 95 is pressed into themetal plate material 20 at a right angle (90 degrees) with respect to a plate surface. Then, the wedgedpunch 95 is pulled out of themetal plate material 20. As a result, arecess 90 with avertical surface 92 is formed as shown inFIG. 9B . Next, as shown inFIG. 9C , thepunch 95 is pressed into an area near thevertical surface 92 of theresultant recess 90. This folds thevertical surface 92 of therecess 90, and the area that has been thevertical surface 92 forms an undercut 91. An undercut formed by the steps shown inFIGS. 8A to 8D andFIGS. 9A to 9D achieves the same advantages as those of the aforementioned embodiments. - An undercut may also be formed as follows. As shown in
FIG. 22A , recesses 90 in a pair are formed with the aforementioned wedgedpunch 95 such thatvertical surfaces 92 in a pair are arranged close to each other. Next, as shown inFIG. 22B , a wedgedpunch 96 of a different shape is pressed into between therecesses 90 in a pair, specifically between thevertical surfaces 92 in a pair. The wedgedpunch 96 has a shape that is tapered from its proximal end toward its distal end, which is configured to be pressed into themetal plate material 20. Thus, during the press, the distance between the base end of thepunch 96 and eachvertical surface 92 becomes longer than the distance between the tip of thepunch 96 and the correspondingvertical surface 92. This folds thevertical surfaces 92 of the tworecesses 90, and the areas that have been thevertical surfaces 92 form undercuts 91 as shown inFIG. 22C . According to this process, multiple undercuts can be formed simultaneously in a single course of work. - An undercut may also be formed with a
punch 180 as follows. As shown inFIG. 23A , thepunch 180 has afirst processing surface 181, asecond processing surface 182 continuous with thefirst processing surface 181, and athird processing surface 183 continuous with thesecond processing surface 182. A vertex between the second and third processing surfaces 182 and 183 is defined as aprocessing tip 184. Thepunch 180 as a whole is tapered toward theprocessing tip 184. - First, as shown in
FIG. 23A , theprocessing tip 184 of thepunch 180 is pressed into themetal plate material 20 such that thefirst processing surface 181 becomes at a right angle with respect to a plate surface of themetal plate material 20. - This forms a
recess 190 in themetal plate material 20 as shown inFIG. 23B . Therecess 190 has a first processedsurface 191 corresponding to thefirst processing surface 181, a second processedsurface 192 corresponding to thesecond processing surface 182, and a third processedsurface 193 corresponding to thethird processing surface 183. The first processedsurface 191 is at a right angle with respect to the plate surface. Therecess 190 further has a first processedridge 194 formed between the first and second processedsurfaces ridge 195 formed between the second and third processedsurfaces - Next, as shown in
FIG. 23C , thepunch 95 is pressed into an area near the first processedsurface 191 of theresultant recess 190. At this time, thepunch 95 is pressed such that the distance between the tip of thepunch 95 and the plate surface of themetal plate material 20 becomes the same as the distance between the first processedridge 194 and the plate surface of themetal plate material 20. - This folds the first processed
surface 191 relative to the first processedridge 194, so that the first processedsurface 191, which has been a vertical surface, forms an undercut 196 as shown inFIG. 23D . This process can be conducted easily since it uses a smaller amount of the plate material to be folded from a vertical state, compared to the case where an undercut is formed by the steps shown inFIGS. 8A to 8C . - In the first embodiment, the
recess portion 30 has two recess rows 31. Therecess portion 30 may also have only one recess row as in the second embodiment or may have three or more recess rows. These achieve the same advantages as those of the first embodiment. - While the two recess rows 31 extend in the longitudinal direction of the
segment 12 in the first embodiment, they are not always required to extend in this longitudinal direction. - The
third recess 34 is deeper than the first andsecond recesses third recess 34 may be the same in depth as the first andsecond recesses - In the first embodiment, the
undercuts 32 a to 34 a may tilt in the same direction. This achieves the same advantages as the advantages (1) to (3) and (5) of the first embodiment. Further, in the second embodiment, undercuts formed at therecess portion 130 may tilt in the same direction. - Although the
recess portions - Although two first
inner claws 15 and two secondinner claws 16 are formed in the first embodiment, only one firstinner claw 15 and only one secondinner claw 16 may be formed. The first and secondinner claws segment 12. One the first and secondinner claws inner claw 121, or three or more firstinner claws 121 may be formed. - Although an undercut is formed at each of the first to
third recesses third recesses 32 to 34. - In the first and second embodiments, the number of the
segments 12 is ten and eighteen, respectively. However, the number of thesegments 12 is not limited to these numbers and it may be changed as necessary depending on a structure. - In the first embodiment, the
cylindrical material 22 is formed by rolling up theblank material 21 punched out of themetal plate material 20 and then thesegments 12 are formed by cutting thecylindrical material 22. Alternatively, thesegments 12 may be punched directly out of themetal plate material 20. - In the second embodiment, the
escape grooves 154 may be omitted from the scrapingpunch 150.
Claims (6)
1. A commutator comprising:
a cylindrical insulator, and
a plurality of commutator pieces formed on an outer circumferential surface of the insulator, the commutator pieces being arranged side by side in a circumferential direction of the insulator, wherein
the commutator pieces are each composed of a conductive plate material,
the commutator pieces each include
a connection claw, which extends outward in a radial direction of the insulator and is configured to be electrically connected to an armature coil, and
an engagement claw extending inward in the radial direction of the insulator, the engagement claw engaging with the insulator, and
the commutator pieces each include a recess portion with an undercut formed in a surface facing inward in the radial direction of the insulator.
2. The commutator according to claim 1 , wherein
each commutator piece includes opposite ends with respect to an axial direction of the insulator, with engagement claws arranged at the opposite ends, and
each recess portion is provided between two of the engagement claws with respect to the axial direction of the insulator.
3. The commutator according to claim 1 , wherein
the recess portions are first recess portions
the undercuts are first undercuts each having a first tilt direction,
each commutator piece further includes a second recess portion, and
the second groove portion has a second undercut having a second tilt direction different from the first tilt direction.
4. The commutator according to claim 1 , wherein
each commutator piece has two or more of the recess portions, and
the depth of each of the recess portions that are formed in an area facing one of the connection claws is deeper than that of the recess portions formed in other areas.
5. The commutator according to claim 1 , wherein
each engagement claw is formed by forming a cut in the surface of the corresponding commutator piece facing inward in the radial direction of the insulator and raising the cut, and
the recess portions each include a resultant groove resulting from formation of one of the engagement claws.
6. The commutator according to claim 5 , wherein
each commutator piece has two or more of the engagement claws that are spaced in the circumferential direction of the insulator, and
the engagement claws are each formed by forming a cut and raising the cut, wherein the cut is formed in an area of the commutator piece different from an edge of the commutator piece with respect to the circumferential direction of the insulator.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/865,071 US10186937B2 (en) | 2012-09-21 | 2018-01-08 | Method of manufacturing commutator segments with claws and tilted recesses |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2012208071A JP5996346B2 (en) | 2012-09-21 | 2012-09-21 | Commutator |
JP2012208070 | 2012-09-21 | ||
JP2012-208071 | 2012-09-21 | ||
JP2012-208070 | 2012-09-21 | ||
JP2013-179492 | 2013-08-30 | ||
JP2013179492A JP6180849B2 (en) | 2012-09-21 | 2013-08-30 | Commutator |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US15/865,071 Continuation US10186937B2 (en) | 2012-09-21 | 2018-01-08 | Method of manufacturing commutator segments with claws and tilted recesses |
Publications (1)
Publication Number | Publication Date |
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US20140084745A1 true US20140084745A1 (en) | 2014-03-27 |
Family
ID=50319615
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/029,611 Abandoned US20140084745A1 (en) | 2012-09-21 | 2013-09-17 | Commutator |
US15/865,071 Active US10186937B2 (en) | 2012-09-21 | 2018-01-08 | Method of manufacturing commutator segments with claws and tilted recesses |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US15/865,071 Active US10186937B2 (en) | 2012-09-21 | 2018-01-08 | Method of manufacturing commutator segments with claws and tilted recesses |
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US (2) | US20140084745A1 (en) |
CN (2) | CN103682909A (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11217952B2 (en) * | 2016-10-25 | 2022-01-04 | Schleifring Gmbh | Slip ring module |
EP3740382B1 (en) | 2018-01-16 | 2022-05-25 | CSEM Centre Suisse d'Electronique et de Microtechnique SA - Recherche et Développement | Method for manufacturing a 3d electromechanical component having at least one embedded electrical conductor |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN108098329B (en) * | 2017-12-22 | 2023-06-20 | 山东大学 | Automatic assembling device and method for rectifier bridge of automobile generator |
CN114421664B (en) * | 2021-12-17 | 2023-12-12 | 浙江聚得机电科技有限公司 | Motor rotor assembly |
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EP3740382B1 (en) | 2018-01-16 | 2022-05-25 | CSEM Centre Suisse d'Electronique et de Microtechnique SA - Recherche et Développement | Method for manufacturing a 3d electromechanical component having at least one embedded electrical conductor |
Also Published As
Publication number | Publication date |
---|---|
CN107257075B (en) | 2021-06-25 |
US20180131257A1 (en) | 2018-05-10 |
CN107257075A (en) | 2017-10-17 |
CN103682909A (en) | 2014-03-26 |
US10186937B2 (en) | 2019-01-22 |
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