US3863336A - Method of manufacturing flat-type rotors - Google Patents

Method of manufacturing flat-type rotors Download PDF

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Publication number
US3863336A
US3863336A US342412A US34241273A US3863336A US 3863336 A US3863336 A US 3863336A US 342412 A US342412 A US 342412A US 34241273 A US34241273 A US 34241273A US 3863336 A US3863336 A US 3863336A
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US
United States
Prior art keywords
mold
rotor
shaft
flat
armature coil
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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.)
Expired - Lifetime
Application number
US342412A
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English (en)
Inventor
Kunihiro Noto
Hiroaki Mizoguchi
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Hitachi Ltd
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Hitachi Ltd
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Publication date
Application filed by Hitachi Ltd filed Critical Hitachi Ltd
Priority to US05/530,281 priority Critical patent/US3997806A/en
Application granted granted Critical
Publication of US3863336A publication Critical patent/US3863336A/en
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Expired - Lifetime legal-status Critical Current

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine
    • Y10T29/49011—Commutator or slip ring assembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine
    • Y10T29/49012—Rotor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling

Definitions

  • This invention relates to a rotor of a flat-type motor and the method of making the same, and more particularly to aflat-type electric motor wherein a coil is wound in a flat space to form an armature coil.
  • a print motor has been known as one of flat-type motors having a short length in the axial direction.
  • the armature circuit is formed by arranging conductive pieces and insulating materials alternately and connecting by welding the ends of the conductive pieces than motors in which the armature circuit is formed by print wiring.
  • the conductive pieces are not accumulated on'an insulating plate but arrangedlaterally at equal intervals. Therefore, the length in the axial direction of the rotor is equal to the sum of the thickness of the insulating plate and the thickness twice as large as the thickness of the conductive pieces.
  • the print motor of this type has a good response because the moment of intertial is small, and accordingly is commonly used as a servomotor.
  • the feature of flat-type motors having a flat appearance characterizes the use of the flat-type motors in comparison with general cup-like magnet motor.
  • the flat type motors are preferred from the viewpoint of design and saving of space, for example in case of motors for blowers employed in air conditioners or cooling and heating apparatus for automobiles.
  • blowers for car heaters or car air conditioners generally comprising a sirocco fan and a cup-shaped motor
  • the commutator surface can be easily made parallel to the shaft in a print motor by forming an armature coil and a commutator portion separately and connecting the both electrically, it is impractical and cannot be put into practical use due to its low work efficiency.
  • the second reason is that the print motor cannot be easily manufactured satisfying various motor dimensions. This is because the armature circuit portion is processed by punching and the like and accordingly a large number of motors of the same dimension can be advantageously manufactured, but it is impractical to manufacture certain amount of motors of various dimensions since a great cost and long time is necessary to prepare the different molds. For example, in case of motors to be used for cooling and heating apparatus for automobiles, various dimensions are required to comply with various types of car models and various requirements of customers and the number of the respective dimensions is not always properly large.
  • the primary object of the present invention is to provide a rotor of a flat-type motor having short axial length, small size, small weight and low price, and a method of manufacturing the same.
  • Another object of the present invention is to provide a rotor of a flat-type motor having high performance and being able to be manufactured with any dimensions required, and a method of making the same.
  • the features of the present invention lies in manufacturing a rotor by winding in place an armature coil by This construction, however, hinders smoothair flow within the fan and decreases the effective cross section of the fan and lowers the fan efficiency. If the motor is made flat in shape, the axial length thereof is markedly short and the outer diameter of the motor may be smaller than the outer diameter of the fan, and accordingly, the blower can be made compact as a whole and there is no need to decrease the effective cross section of the fan.
  • print motors have not been put into practical use in the above mentioned filed for the following reason.
  • the first reason is that the print motor is disadvantageous from the viewpoint of noise, vibration, life and so forth.
  • a part of the armature coil serves as a commutator and is subject to brush pressure in the axial direction, and accordingly, the armature is comparatively weak in comparison with the'general cup-shaped magnet motor and high accuracy in processing the commutator cannot be expected, and the commutator portion is deformed during revolution due to the brush pressure, the brush touch to the coil is affected by thrust, and the number of commutator seguseof a disc-like jig having pins fixed thereto, arranging a shaft at the center of the coil, placing the coil with the shaft in a mold employing said jig, and injecting a resin into the mold to integrally mold the coil and the shaft to form a rotor.
  • FIG. 4 is a side view partly in section of a first mold employed in this invention
  • FIG. 5 is a front view of the first mold shown in FIG.
  • FIG. 6 is a front view of a second mold employed in the present invention.
  • FIG. 7 is a side view partly insection showing the second mold
  • FIG. 9 is a front view showing the winding of a coil wound in the first mold
  • FIG. 8 is a longitudinal sectional view of a commutafirst mold showing the winding of a coil provided therein, and r integrally. formed with the shaft and a space 23 corresponding to the pin holes if formed (FIG. 2). Further,
  • the reference numeral 1 indi-. cates a left housing, 1 indicates a right housing, and 2 and 3 indicate respectively magnets fixed to the interior surfaces thereof.
  • The. numeral 4 shows a rotor fixed to a shaft 5 which in turn is supported by bearings'6 and 6'.
  • the reference numeral 7 indicates a commutator.
  • the numeral8 denotes a brush assembly which com.-
  • FIGS. 4 to 11 A first'mold l2shown in FIGS.
  • FIG. 4 and 5 is'pr'ovided with outer pins13 and inner pins 14 of the same number concentrically arranged at equal intervals.
  • the inner and outer pins are illustrated in FIG. 4 as being integral with the firstmold 12, but is it possible to fix these pins by any known means.
  • the first mold I2 is further provided with resin injection ports 15 and air holes 16.
  • a coil 9 is wound around the outer pins 13 and inner pins 14 as shown in FIGS. 9 and 10 by use of a conductive material 9 (FIG.3).
  • the outer pins 13 may be made oval in shape or comprise combinations of two pins in order that the coil 9 may be wound more widely than that shown in FIG. 9 and the effective magnetic flux may increase.
  • the shaft 5 is disposed at the center of the first' mold 12 and the terminal end 17 of the coil 9 is connected with a riser 18 of a" commutator 7 as shown in FIG. 8.
  • the commutator 7 is molded and inserted into the shaft 5'in advance. Further, the shaft 5 is provided with a core -cylinder 11 made of iron-inserted thereinto.
  • The'second mold '19 is provided with outer pinholes 20 and inner pin holes 21 corresponding to the outer pins 13 and inner pins 14 of the first mold 12,. respectively.
  • a space 22 for a rotor is formed with the first and the second molds shaft 5 simultaneously with the molding of thecoils. At the time of winding coil 9 or combining the second mold with the first, it sometimes happens that the insulating cover orshield of the coil comes off, which results in faulty insulation.
  • One of the countermeasures for this trouble is to provide a'projection on the inner surface of the first and second molds so that the coil 9 may belocated at the center of the space before molding and uniform small spaces may be obtained between the side face of the coil and the inner surface of the first "and second molds, whereby the side face of the coil is can be properly determined according to the shapeof the parts of the motor'and the method ofmanufacture.
  • FIG. 12 Another embodiment of the method of manufactur ing the armature coil in'accordance with the present invention is shownlin FIG. 12. In this embodiment, the
  • pins of the first mold 12 comprise radially extending elongated pins 22' serving partly as said outer pins 13 and partly as said'inner pins 14 of the first embodiment.
  • the shaft 5 and the commutator 7 are inserted into the first mold 12 at the time of winding coil.
  • the end of the coil 17 is connected with the riser 18 of the commutator 7 when a conductive material 9 is wound in a coil around the pins 22 to form an armature coil 9. Thereafter, the whole assembly is molded into a unit.
  • the spaces 23 formed after removing the molds from the molded coil as shown in FIGS. 2 and 3 have an effect of making an air flow when the rotor rotates and results in cooling of the rotor. Further, thespaces 23 can also be used tofill proper material with in order to I balance the rotor.
  • the magnetic flux makes a closed loop through the magnet 2(N) magnet 3 (S) right housing I" left housing 1 magnet 2.
  • the amount of magnetic flux between the magnet 2 and the magnet 3 influences the performance of the rotor.
  • the amount of magnetic flux 'at this portion decreases as the length of the space between the magnets 2 and 3 increases.
  • the thickness of the armature coil can be further decreased by increasing the number of coils to reduce the number of conductive members per coil.
  • the number'of coils is increased, the number of pins and the number of commutator segments increase and accordingly the winding and connecting work of the coils becomes markedly troublesome.
  • the diameter of the pins is naturally made small and accordingly the strength of a pin is lowered.
  • the operation to make the pins 13, l4 of the first mold l2 mated with the pin holes 20, 21 of the second. mold 19 becomes difficult and the life of the molds-is shortened.
  • FIG. 13 shows the shape and dimensions of the motors used in the experiments, wherein FIG. 13a shows a motor made in accordance with the present invention, FIG. 13b shows a print motor, and FIG. 13c showsa cup-shaped motor.
  • the motor shown in FIG. 13a manufactured in accordance with the present invention was made with nineteen coils in which the number of windings of the conductive wire per coil was 13 with a wire of 0.6mm diameter, the outer diameter of the rotor was 106mm,.and the air gap was 5.6mm.
  • the continuous rated life thereof was proved to be longer than 3,000 hours and output of 50W and efficiency of 62 percent were obtained.
  • the efficiency of 62 percentof the motor of this invention was superior to 50 percent of the print motor and 55 percent of the cup-shaped magnet motor. Further, the motor of this invention was proved to be superior even from the viewpoint of temperature rise and noise.
  • the cup-shaped motor Since the rotor of the cup-shaped motor is generally made by winding an armature coil around an armature core comprising piled up iron or silicon steel plates, an eddy current loss and hysteresis loss are generated at the time of revolution ofthe armature and the efficiency is lowered. Further, because of its great weight, there is mechanical loss due to inertial and loss of bearing abrasion.
  • the manufacture of a rotor and integration of the rotor with the shaft and commutator can be carried out markedly easily, the motor can be manufacture at a considerably low cost.
  • the motor made in accordance with the present invention has the following advantages.
  • the number and diameter of the coil windings can be freely selected and the rotor can be accomodated to various types of molds and process-
  • the armature'coils of the print motor are generally made by punching a copper plate, and accordingly there is a limit in the thickness of the plate to be punched. Therefore, the thickness of the coil cannot be made over a predetermined value and the electric resis-.
  • the motor in accordance with the present invention is applicable not only'to said automobiles but also to servomotors utilizing the feature thereof that the weight of the armature is small.
  • the motor made in accordance with the present invention is suitable for a tape recorder and makes the size of the tape recorder compact when adapted thereto.
  • Method of manufacturing a rotor for a flat-typ motor comprising steps of: 1
  • first mold having pins fixed thereto for winding coils therearound and having a surface to define the outer configuration of one side of the rotor to be made, a winding wire about said pins and on to a flat surface of said first mold to form coils and connecting said coils to said commutator to form an armature coil, combining a second mold with said first mold, said second mold having pin holes-to be mated with said pins and having a space define the outer configuration of a second side of the rotor, said first and second molds being further provided with a space to retain the shaft and one of the molds being provided with a space to retain the commutator, and
  • Method of manufacturing a rotor for a flat-type motor comprising the steps of:
  • said mold is formed of a first mold section and a second mold section, said first and second mold sections forming a cavity therebetween corresponding to the outerconfiguration of the rotor, and said first mold section serving as said disc-like 8.
  • first and second mold sections are each formed with at least one projection on respective surfaces forming said cavity to space said armature coil from the surfaces of said first and second mold sections.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Dc Machiner (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
US342412A 1972-03-22 1973-03-19 Method of manufacturing flat-type rotors Expired - Lifetime US3863336A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US05/530,281 US3997806A (en) 1972-03-22 1974-12-06 Rotor of flat-type motor

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP47028147A JPS4895506A (ko) 1972-03-22 1972-03-22

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US05/530,281 Continuation-In-Part US3997806A (en) 1972-03-22 1974-12-06 Rotor of flat-type motor

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US3863336A true US3863336A (en) 1975-02-04

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Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3955273A (en) * 1974-02-01 1976-05-11 Hitachi, Ltd. Method of manufacturing flat type wound armatures
US3979620A (en) * 1974-07-03 1976-09-07 Canadian General Electric Co. Ltd. Segmental discoidal winding structure for dynamoelectric machines
US4008410A (en) * 1974-03-13 1977-02-15 Canadian General Electric Company Limited Commutator for discoidal armature
US4068143A (en) * 1973-12-19 1978-01-10 General Electric Company Discoidal winding for dynamoelectric machines
DE2741423A1 (de) * 1976-09-14 1978-03-16 Olympus Optical Co Laeufer fuer kleine kernlose elektromotoren sowie ein verfahren zu ihrer herstellung
DE2831518A1 (de) * 1977-07-18 1979-02-01 Acr Electronics Elektrische maschine
US4164675A (en) * 1976-10-19 1979-08-14 Olympus Optical Company, Ltd. Rotor of coreless motor and method of manufacturing same
US4321496A (en) * 1981-03-02 1982-03-23 General Electric Company Discoidal winding coil structure for axial gap dynamoelectric machines
US4420875A (en) * 1979-12-05 1983-12-20 Mavilor Systemes Method of mounting and casting a flat rotor
US4598222A (en) * 1983-12-20 1986-07-01 Mitsuba Electric Manufacturing Co., Ltd. Direct current machine
WO1986003898A1 (en) * 1984-12-21 1986-07-03 Robert Bosch Gmbh Disc rotor for electric machine with axial air gap
US4633576A (en) * 1983-06-22 1987-01-06 Yamamoto Electric Industrial Co., Ltd. Method of producing armature winding and apparatus therefor
DE3640210A1 (de) * 1985-11-25 1987-05-27 Matsushita Electric Ind Co Ltd Verfahren und vorrichtung zur herstellung des ankers fuer einen flachen motor
US4677334A (en) * 1984-09-13 1987-06-30 The Globe Tool And Engineering Company Flat coil dynamoelectric device with encapsulated preform
US4746844A (en) * 1985-07-16 1988-05-24 Maghemite Inc. Control and operation of brushless continuous torque toroid motor
US4756075A (en) * 1984-09-13 1988-07-12 The Globe Tool And Engineering Company Method and apparatus for manufacturing a preform for a flat coil dynamoelectric device
US5482646A (en) * 1993-03-05 1996-01-09 Church & Dwight Co., Inc. Powder detergent composition for cold water laundering of fabrics
US6812615B1 (en) * 1998-04-16 2004-11-02 John Patrick Ettridge Electric motor
US6841112B1 (en) * 2001-04-11 2005-01-11 Comair Rotron, Inc. Balanced rotor
RU2560930C2 (ru) * 2013-07-30 2015-08-20 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Воронежский государственный технический университет" Ротор торцевого электродвигателя
RU2654562C2 (ru) * 2016-01-20 2018-05-21 Федеральное государственное бюджетное образовательное учреждение высшего образования "Воронежский государственный технический университет" Ротор электродвигателя торцевой

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS50103601A (ko) * 1974-01-23 1975-08-15
JPS5615916Y2 (ko) * 1974-12-17 1981-04-14
JPS5171905A (ja) * 1974-12-18 1976-06-22 Hitachi Ltd Katsupugatakaitenshi
JPS52142202A (en) * 1977-05-13 1977-11-28 Hitachi Ltd Flat type rotor

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2759116A (en) * 1954-11-26 1956-08-14 John P Glass Induction type tachometer
US3077658A (en) * 1960-04-11 1963-02-19 Gen Dynamics Corp Method of manufacturing molded module assemblies
US3212170A (en) * 1961-04-28 1965-10-19 Black & Decker Mfg Co Armature and method of making the same
US3524250A (en) * 1968-04-08 1970-08-18 Circuit Res Co Method of manufacturing electrical wire wound machines
US3599325A (en) * 1969-06-09 1971-08-17 Photocircuits Corp Method of making laminated wire wound armatures

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2759116A (en) * 1954-11-26 1956-08-14 John P Glass Induction type tachometer
US3077658A (en) * 1960-04-11 1963-02-19 Gen Dynamics Corp Method of manufacturing molded module assemblies
US3212170A (en) * 1961-04-28 1965-10-19 Black & Decker Mfg Co Armature and method of making the same
US3524250A (en) * 1968-04-08 1970-08-18 Circuit Res Co Method of manufacturing electrical wire wound machines
US3599325A (en) * 1969-06-09 1971-08-17 Photocircuits Corp Method of making laminated wire wound armatures

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4068143A (en) * 1973-12-19 1978-01-10 General Electric Company Discoidal winding for dynamoelectric machines
US3955273A (en) * 1974-02-01 1976-05-11 Hitachi, Ltd. Method of manufacturing flat type wound armatures
US4008410A (en) * 1974-03-13 1977-02-15 Canadian General Electric Company Limited Commutator for discoidal armature
US3979620A (en) * 1974-07-03 1976-09-07 Canadian General Electric Co. Ltd. Segmental discoidal winding structure for dynamoelectric machines
DE2741423A1 (de) * 1976-09-14 1978-03-16 Olympus Optical Co Laeufer fuer kleine kernlose elektromotoren sowie ein verfahren zu ihrer herstellung
US4203048A (en) * 1976-09-14 1980-05-13 Olympus Optical Co., Ltd. Coil support for disc rotor of coreless motor
US4164675A (en) * 1976-10-19 1979-08-14 Olympus Optical Company, Ltd. Rotor of coreless motor and method of manufacturing same
DE2831518A1 (de) * 1977-07-18 1979-02-01 Acr Electronics Elektrische maschine
US4420875A (en) * 1979-12-05 1983-12-20 Mavilor Systemes Method of mounting and casting a flat rotor
US4321496A (en) * 1981-03-02 1982-03-23 General Electric Company Discoidal winding coil structure for axial gap dynamoelectric machines
US4633576A (en) * 1983-06-22 1987-01-06 Yamamoto Electric Industrial Co., Ltd. Method of producing armature winding and apparatus therefor
US4598222A (en) * 1983-12-20 1986-07-01 Mitsuba Electric Manufacturing Co., Ltd. Direct current machine
US4756075A (en) * 1984-09-13 1988-07-12 The Globe Tool And Engineering Company Method and apparatus for manufacturing a preform for a flat coil dynamoelectric device
US4677334A (en) * 1984-09-13 1987-06-30 The Globe Tool And Engineering Company Flat coil dynamoelectric device with encapsulated preform
WO1986003898A1 (en) * 1984-12-21 1986-07-03 Robert Bosch Gmbh Disc rotor for electric machine with axial air gap
US4746844A (en) * 1985-07-16 1988-05-24 Maghemite Inc. Control and operation of brushless continuous torque toroid motor
US4790063A (en) * 1985-11-25 1988-12-13 Matsushita Electric Industrial Co., Ltd. Method and apparatus for fabricating armature of flat motor
DE3640210A1 (de) * 1985-11-25 1987-05-27 Matsushita Electric Ind Co Ltd Verfahren und vorrichtung zur herstellung des ankers fuer einen flachen motor
DE3640210C2 (ko) * 1985-11-25 1992-12-10 Matsushita Electric Industrial Co., Ltd., Kadoma, Osaka, Jp
US5482646A (en) * 1993-03-05 1996-01-09 Church & Dwight Co., Inc. Powder detergent composition for cold water laundering of fabrics
US6812615B1 (en) * 1998-04-16 2004-11-02 John Patrick Ettridge Electric motor
US6841112B1 (en) * 2001-04-11 2005-01-11 Comair Rotron, Inc. Balanced rotor
RU2560930C2 (ru) * 2013-07-30 2015-08-20 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Воронежский государственный технический университет" Ротор торцевого электродвигателя
RU2654562C2 (ru) * 2016-01-20 2018-05-21 Федеральное государственное бюджетное образовательное учреждение высшего образования "Воронежский государственный технический университет" Ротор электродвигателя торцевой

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Publication number Publication date
JPS4895506A (ko) 1973-12-07

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