Classifications

• • 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
  • H01R39/32—Connections of conductor to commutator segment
• • 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
• • 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

Definitions

• the invention relates to a method for producing an electrically conductive and mechanically strong connection of armature winding wires to the slats of a hook collector, in which the wires laid around the hooks of the collector slats during the winding process without stripping are fixed by bending the hooks and the free ones The ends of the hooks are connected to the associated collector lamellae by ultrasonic welding.
• the invention also includes devices which are particularly suitable for carrying out the method, with a sonotrode which can be moved relative to the hook collector for bending the hooks and ultrasonically welding the hook ends with the collector lamellae.
• the collector lamellae are to be rolled out on a contacting pool of a sonotrode and / or vice versa, as a result of which both the enamel insulation of the armature winding wires flake off during the welding process and at the same time a mechanical connection between hooks and slats should be created by ultrasonic welding.
• the desired peeling off of the lacquer insulation layer does not take place uniformly and / or completely, so that this method does not lead to reproducible electrical connections on the individual lamellae of a collector, as a result of which it is not suitable for the mass production of collectors because of the high scrap rate.
• a method has also already been proposed (DE-OS 24 16 411) in which, in order to produce an electrically conductive and mechanical connection between the lamellae of a hook commutator and armature winding wires, the insulation on the wire loops is first removed before it is pulled around the Hooks are placed. The hooks are then bent over and press welded to the fin ends.
• the partial removal of the lacquer insulation from the wire loops before they are attached to the hook is a complex work step that has to be carried out for each wire loop.
• the lamella ends are alternately arranged on different levels, which further increases the cost of manufacturing such collectors.
• the present invention has for its object to provide a method by means of which good electrically conductive connections to the armature winding wires can be achieved on all slats of a hook collector, without the slat ends having to be arranged in different planes to avoid short circuits.
• the problem is solved, starting from the genus described at the outset, according to the invention by a method which is characterized in that, before the hooks are bent, the lacquer insulation layer at the locations of the hooks is at least partially destroyed thermally and / or mechanically, and that the residues or residues of the lacquer insulation layer when the hook is bent under the action of ultrasound are at least partially removed from the wire surfaces intended for contact with the inner surface of the hook by the ultrasonic vibrations before the hook ends are welded to the collector lamellae.
• the thermal and / or mechanical destruction of the lacquer insulation layer on the wires already placed around the hooks of the collector lamellae avoids previous stripping steps and, on the other hand, the stripping is spatially restricted to the areas of the wires placed around the hooks, so that short circuits between adjacent wires are excluded despite the arrangement of the wire loops with the same radial distances from the axis of rotation of the collector.
• the residues or residues of the coating insulation layer which occur during the thermal and / or mechanical destruction of the coating insulation layer are displaced or removed from the contact area under the action of ultrasound before the hooks are completely bent over and welded at their ends to the collector lamellae. In this way constant metallic contact surfaces between the lamellae and hooks on the one hand and the associated wire surfaces.
• the method is advantageously carried out in such a way that the residues or remnants of the lacquer insulation layer, insofar as they are not completely removed, when bent by means of the ultrasonic vibrations into a
• the wedge-shaped space formed on the inside of the hook and the surface of the lamellae are displaced. This results in defined zones of metallic contact between the wires, the inside surface of the hook and the lamella surface on each hook.
• the method is expediently carried out in such a way that the lacquer insulation layer is acted on thermally and / or mechanically to at least partially destroy the lacquer insulation layer approximately in the longitudinal direction of the collector by the distances between the hook ends and the lamella surface. In this way, sufficiently large surface areas of the wires can be reliably freed from the coating insulation layer.
• the coating insulation layer can be at least partially removed by contacting a highly heated body with the wires. But also by flaming or inflating highly heated air on the wires there is an effective attack on the coating insulation layer. Burning off the lacquer insulation layer by means of a laser beam is also possible. Finally, it is also possible to simultaneously inductively heat all of the wires of a collector at the locations of the hooks, as a result of which the lacquer insulation layer on all hooks is attacked simultaneously.
• the lacquer insulation layer which is brought about by mechanical means.
• the lacquer insulating layer can also be removed by brushing off the wires at the desired locations.
• the method can also be carried out so that d
• the coating insulation layer is attacked in addition to the thermal processes described or exclusively by blasting the wires with fine solid particles. It goes without saying that if mechanical methods are additionally used, these are expediently brought into effect following the thermal methods.
• the device is advantageously designed such that an inductively or electrically heatable ring is arranged concentrically to the hook collector and at a radial distance from it, which is arranged on a holder which is displaceably guided parallel to the axis of the hook collector is fastened.
• the arrangement of the device is advantageously such that at least one burner or hot air nozzle or at least a distance from it on the circumference of the collector.
• a laser head is arranged, the beam direction of which forms an acute angle with the collector axis and meets the wires placed around the hooks.
• the device is advantageously designed such that a ring with a steel bristle or the like is arranged concentrically to the hook collector and at a radial distance therefrom, which is attached to a ring around the axis of the Hook collector rotatable and parallel movable holder is attached.
• the device design for the destruction of the varnish insulating layer by blasting the wires with fine solid particles is advantageously characterized in that at least one jet nozzle for ejecting fine solid particles is arranged at a high speed on the circumference of the collector and the jet direction thereof is aligned with the Collector axis forms an acute angle and hits the wires placed around the hooks.
• an advantageous device variant provides that an induction coil is provided concentrically to the hook collector and at a radial distance from the hooks, the induction coil and the hook collector being axially displaceable relative to one another are arranged.
• the axially displaceability enables a relative displacement between the induction coil and the hook collector, so that after the wire loops have been heated directly by induction, the hooks for the attack of the sonotrode are exposed.
• FIG. 1 shows the section shown broken off through a collector lamella corresponding to line II-II in FIG. 1,
• FIG. 1 shows a broken longitudinal section through a collector lamella with an induction coil
• Fig. 11 is a perspective view of a
• Anchor with collector and a rotatable sonotrode opposite the collector.
• the collector 1 shown in FIG. 1 has a plurality of lamellae 2 located at equal distances in its cylinder circumferential surface, a hook 3 being formed on one end thereof.
• the hooks 3 are initially coincident in a bent position, as shown in FIGS. 1 to 9.
• the bent position enables the hooks 3 to be looped around with the armature winding wires 5.
• the lacquer insulation layer 6 located on the armature winding wires 5 is at least partially destroyed thermally and / or mechanically at the locations of the hooks 3 .
• the lacquer insulation layer acts approximately in the longitudinal direction of the collector T through the distances, which are located between the ends of the hooks 3 and the surfaces of the slats 2.
• a ring 7 is arranged concentrically to the collector 1 and with a radial spacing forming a gap to the collector circumferential surface, which ring is fastened to a holder 8 which can be moved parallel to the axis of the collector 1.
• the ring 7 can by inductive z. B. heated up to red heat. If the ring 7 heated in this way is brought into contact with the armature winding wires 5 inserted into the hooks 5, as indicated in FIG. 3, the lacquer insulating layer 6 is thermally damaged at the points of contact and in the immediate vicinity so that in this area it detaches from the wires. In this case, the thermal action takes place simultaneously for all hooks 3 or the armature winding wires 5 inserted in the hooks. At the same time as contacting the ring 7 with the wires, a relative rotation between the collector 1 and the
• Ring 7 can be provided, whereby at the same time it is also mechanically scraped onto the lacquer insulation layer at the points in question.
• At least one burner or hot air nozzle 9 is fixedly arranged on the circumference of the collector T and at a distance from it, from which a flame 10 or highly heated air can be brought out which the lacquer insulation layer 6 within the hook 3 is removed from the armature winding wires 5.
• the collector 1 rotates about its axis in order to bring all the wires in the hook 3 into contact with the flame 10 or the hot air evenly.
• 5 shows a similar device, in which, however, a laser head T1 is arranged instead of a burner or hot air nozzle, from which a laser beam 12 emerges directed onto the armature winding wires 5 inserted into the hooks 3.
• the laser head 11 is arranged in a stationary manner, while the collector 1 is provided for rotation about its axis.
• an induction coil 13 is provided concentrically to the collector 1, which has a radial distance to the hooks 3 on all sides, i.e. this does not affect.
• a relative rotation does not have to be provided between induction coil 13 and collector 1, however, induction coil 13 and collector 1 must be arranged such that they can be displaced relative to one another in the axial direction, so that after the induction heating of the armature winding located in hooks 3 wires 5 the hooks 3 can be exposed for sonotrode attack.
• the lacquer insulating layer 6 is thermally damaged so that a metallic contact between the hook lamellae and the wires can be brought about in the subsequent operations.
• a ring 14 is provided concentrically with the collector 1 and at a radial distance therefrom, the ring being bristled with steel bristles 15 or the like on its circumference. is busy.
• the ring 14 and the collector 1 can be axially displaced relative to one another and, in addition, a relative rotation can be brought about between the ring 14 and the collector 1 in order to carry out the brushing process.
• the ring 14 is attached to a holder 16.
• the device shown in FIG. 8 is similar to that which has been described with reference to FIGS. 4 and 5.
• a jet nozzle 17 is arranged on the circumference of the collector 1 and at a distance from it so that the jet of fine solid particles 18 emerging from it strikes the wires 5 placed around the hooks 3.
• the device is designed in such a way that a relative rotation between the jet nozzle 17 and the collector 1 is possible. If the jet nozzle 17 is arranged stationary, the collector 1 must be rotatable about its axis.
• a plurality of jet nozzles 17 can also be provided distributed on the circumference of the collector 1.
• the hooks 3 are bent in succession on the collector 1 with simultaneous exposure to ultrasound as a second process step.
• the sonotrode of an ultrasonic welding device is used as a bending tool.
• FIG. 9 shows a sonotrode 19, on which there are, for example, two different projections 20 and 2t, which are responsible for the shape of the hooks 3 being bent.
• a sonotrode 19 On which there are, for example, two different projections 20 and 2t, which are responsible for the shape of the hooks 3 being bent.
• Immediately by placing one of the projections 20 or 21 on the hook 3 which is still open transmit the ultrasonic vibration of the sonotrode T9 to the hook 3 and, with increasing bending, also to the armature winding wire 5 lying in the hook 3.
• the residues or remnants of the thermally and / or mechanically at least partially destroyed lacquer insulation layer are destroyed by the high-frequency vibrations removed the electrical contact provided surfaces of the Ankenvicklungs wire 5 and stored in a wedge-shaped space 22, which is formed during the bending process between the wire 5, the inner surface of the hook 3 and the surface of the lamella 2.
• the bending process is essentially completed when the hook 3 strikes the surface of the collector plate 2 with its
• the latter is finally brought into the final shape shown in FIG. 9 by ultrasonically welding the hook end to the surface of the lamella 2.
• the armature nickel wire 5 which is also somewhat deformed by the contact pressure, is wrapped over a considerable circumferential area by the hook 3 to form a reliable electrical contact.
• the second process step of bending the hook 3 under the action of ultrasound and the third process step of welding the hook end to the collector lamella 2 follow one another directly overlapping in time.
• FIG. 10 shows that in addition to the wedge-shaped space 22 ', a corresponding gap arrangement 24 of the sonotrode 19 during the bending and welding process results in a further gap space 24 between the
• Wire 5 the inner surface of the hook 3 and the surface of the lamella 2 can be formed, in which residues or remnants of the lacquer insulation layer are also displaced during bending. Also in this c all arises secure metallic contact between the lamella and the hook 3 on the one hand and the armature winding wire 5 on the other.
• the sonotrode 19 rotatable about its axis is provided with a cylindrical sonotrode head 25, the circumferential surface 26 of which is intended for rolling on the cylindrical circumferential surface of the collector 1.
• the circumferential surface 26 there are recesses 27 at regular intervals, which are assigned to the hooks 3 of the collector 1 in such a way that the hooks 3 are received in the recesses 27 when the rolling is carried out by carrying out the described bending and welding process.

Landscapes

• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacture Of Motors, Generators (AREA)
• Motor Or Generator Current Collectors (AREA)

Priority Applications (1)

Applications Claiming Priority (2)

Publications (1)

Family

ID=6365582

Family Applications (1)

Country Status (6)

Cited By (2)

Families Citing this family (20)

Citations (8)

Family Cites Families (3)

• 1988
  • 1988-10-21 DE DE3835818A patent/DE3835818C3/de not_active Expired - Fee Related
• 1989
  • 1989-10-19 WO PCT/DE1989/000668 patent/WO1990004864A1/de not_active Ceased
  • 1989-10-19 US US07/477,930 patent/US5113574A/en not_active Expired - Fee Related
  • 1989-10-19 JP JP1510761A patent/JP2907913B2/ja not_active Expired - Fee Related
  • 1989-10-20 EP EP89119503A patent/EP0370235A1/de not_active Withdrawn
• 1990
  • 1990-06-12 KR KR1019900701248A patent/KR900702604A/ko not_active Withdrawn

Patent Citations (8)

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