WO2003050932A1 - Procede de fabrication d'un commutateur plat et systeme de fabrication correspondant - Google Patents

Procede de fabrication d'un commutateur plat et systeme de fabrication correspondant Download PDF

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Publication number
WO2003050932A1
WO2003050932A1 PCT/JP2002/011218 JP0211218W WO03050932A1 WO 2003050932 A1 WO2003050932 A1 WO 2003050932A1 JP 0211218 W JP0211218 W JP 0211218W WO 03050932 A1 WO03050932 A1 WO 03050932A1
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WO
WIPO (PCT)
Prior art keywords
manufacturing
metal piece
cartridge
flat commutator
commutator
Prior art date
Application number
PCT/JP2002/011218
Other languages
English (en)
Japanese (ja)
Inventor
Shuji Uehara
Hideyuki Minami
Kazuo Iwashita
Yuzo Arakawa
Kazuhiro Yamazaki
Yasuhiro Takebe
Yoshinori Kojima
Takayuki Ishizeki
Kenichi Kanda
Hideki Horiuchi
Masayuki Yoshizawa
Tsugio Yokoo
Original Assignee
Mitsuba Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Mitsuba Corporation filed Critical Mitsuba Corporation
Priority to AU2002344597A priority Critical patent/AU2002344597A1/en
Priority to JP2003551883A priority patent/JP4230358B2/ja
Publication of WO2003050932A1 publication Critical patent/WO2003050932A1/fr

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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
    • 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
    • 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
    • H01R39/06—Commutators other than with external cylindrical contact surface, e.g. flat commutators

Definitions

  • the present invention relates to a method for manufacturing a commutator for a rotating electric machine, and more particularly, to a method for manufacturing a disk-type flat commutator.
  • This flat commutator has a disk-shaped plush contact surface that extends in the radial direction from the rotating shaft, unlike a general cylindrical commutator, and a metal member called commutator metal is molded integrally with synthetic resin. Is done. After integral molding, the commutator metal is cut radially so as to be insulated from each other and separated in the circumferential direction to form a plurality of segments. Then, the brush slides on the brush sliding surface made of the commutator metal from the axial direction, and the armature current is switched.
  • a cutter is used to separate the commutator metal, and a cutter or laser is used to remove the resin between the segments, and slit cutting is performed.
  • each segment is separated in this way, if it has a U-groove for coil mounting on the outer periphery of the segment, it is formed by cutting.
  • the commutator is assembled together with the rotating shaft armature core, coil winding, and the like, and further coated with a synthetic resin to form an armature assembly.
  • the brush sliding surface is finished by cutting to clean the segment surface and adjust its flatness and surface roughness.
  • the first method using a bar has a problem that the yield is not good because many parts are removed by cutting.
  • the amount of cutting is large, the number of man-hours is increased, and the man-hour for assembling the cartridge is also added.
  • segment division accuracy is determined by the accuracy of the cutting tool itself, chuck accuracy during machining, angle indexing accuracy, etc.Therefore, there are many factors that determine the accuracy, and product accuracy tends to vary. There is also.
  • the coil groove is formed in advance at the segment component stage, the accuracy variation associated with the slit processing as described above is reduced.
  • burrs in the coil groove The remainder is a cause of defects in the coil insertion process and fusing process, such as defective coil insertion and conduction. For this reason, it is required to completely remove burrs, and from such a viewpoint, it is desirable that glue itself does not occur.
  • An object of the present invention is to provide a method of manufacturing a flat commutator that can obtain a product with good yield and high accuracy and can reduce man-hours. Disclosure of the invention
  • a method of manufacturing a flat commutator according to the present invention includes: a holder formed of a synthetic resin in a disk shape; and a plurality of segments disposed along one end surface of the holder in an axial direction along a circumferential direction.
  • a step of integrally molding the metal pieces with a synthetic resin in the present invention, a flat type commutator can be obtained by forming a prototype of a segment by forming metal pieces in a chain shape and assembling them into a circle, and then molding this with a resin.
  • a chain can be formed by forming a metal piece into a chain using a progressive press machine with a high processing speed and cutting it in a few minutes, so that a product with high product accuracy can be obtained with high yield. This makes it possible to manufacture highly reliable products at low cost.
  • a cartridge may be mounted on the brush sliding contact surface side, and mold molding may be performed with the cartridge mounted. Further, the continuous metal pieces may be separated into individual metal pieces before the molding, whereby Cutting work that separates the metal pieces is not required, which reduces man-hours and prevents the occurrence of burrs in the circumferential direction during processing and prevents damage to the synthetic resin, thereby improving product reliability.
  • a method of manufacturing a flat commutator according to the present invention includes a holder formed of a synthetic resin in a disk shape, and a plurality of segments disposed along one end surface of the holder in the axial direction along the circumferential direction. Mounting a cartridge having a projection that fits into a gap formed between the metal pieces on the brush sliding contact surface side of the metal piece forming the segment, the method comprising: A step of pressing the vicinity of the gap of the metal piece attached to the force cartridge from the side opposite to the brush sliding surface to bring the gap into close contact with the projection; and Molding the metal piece integrally with synthetic resin.
  • the molding since the molding is performed in a state in which the gap between the metal pieces is in close contact with the projection formed on the cartridge, the synthetic resin does not enter the gap during molding, and the portion of the projection remains the metal as it is.
  • the slit remains as a concave portion between the pieces. For this reason, it is possible to omit the slit cutting after the molding, and to reduce the number of steps. Further, since the slit is formed by the projection of the cartridge, the slit position accuracy can be improved as compared with the slit formation by the blade, and the variation in product accuracy can be reduced.
  • the method for manufacturing a flat commutator of the present invention includes: a holder formed of a synthetic resin in a disk shape; and a plurality of segments disposed along one end surface of the holder in the axial direction along the circumferential direction.
  • a method of manufacturing a flat type commutator comprising: a metal piece forming the segment, on a brush sliding contact surface side, a projection fitted to a coil mounting groove formed in an outer peripheral portion of the metal piece. Mounting a cartridge; pressing the vicinity of the coil mounting groove of the metal piece mounted on the cartridge from the side opposite to the brush sliding contact surface to bring the coil mounting groove into close contact with the projection; A step of integrally molding the metal piece with a synthetic resin while the cartridge is mounted.
  • the coil mounting groove is closely attached to the projection formed on the cartridge. Since the molding is performed in a state in which the coil is inserted, the synthetic resin does not enter the coil mounting groove during molding, and it is possible to prevent resin burrs from being generated in the groove. As a result, the resin burr problem in the groove is solved, and the coil mounting groove can be formed at the same time as the metal piece is formed, significantly reducing the number of man-hours compared to forming the groove later by cutting. can do. Furthermore, by closely attaching the coil mounting groove to the protrusion, the dimension of the groove's shape is corrected in accordance with the protrusion, so that the dimensional accuracy of the coil mounting groove can be improved as compared with the cutting process. It is possible to prevent coil insertion failure at the time of wiring.
  • the manufacturing method of the flat commutator of the present invention comprises: a holder portion formed of a synthetic resin in a disk shape; and a plurality of segments arranged along one circumferential direction on one axial end surface of the holder portion.
  • a method for manufacturing a flat commutator comprising: (a) a step of forming a chain formed by connecting a plurality of metal pieces forming the segment; and (b) a step of forming the chain into a circular shape. (C) arranging the metal pieces along the circumferential direction; and (c) first fitting the gap formed between the metal pieces to the brush sliding contact surface side of the circular assembly.
  • a flat type commutator can be obtained by forming a metal mold into a chain and assembling it into a circle to form a prototype of a segment, and then molding it with a resin.
  • the number of manufacturing steps can be reduced as compared with the conventional method.
  • a chain can be formed by forming a metal piece into a chain using a progressive press machine with a high processing speed and cutting it in a few minutes, so that a product with high product accuracy can be obtained with high yield. This makes it possible to manufacture highly reliable products at low cost.
  • the synthetic resin does not enter the gaps during molding, and the projections remain as recesses between the metal pieces. It remains and becomes a slit. For this reason, it is possible to omit the slit cutting after the molding, and to reduce the number of steps. Further, since the slit is formed by the protrusion of the cartridge, the slit position accuracy can be improved as compared with the slit formation by the blade, and the variation in the product accuracy can be reduced.
  • the continuous metal pieces are separated into individual metal pieces before molding, cutting work that separates the metal pieces after molding is not required, reducing man-hours and reducing the circumferential direction during processing. It is possible to prevent the occurrence of burrs and damage to the synthetic resin, thereby improving product reliability.
  • a step of forming a boss portion that protrudes in the axial direction on the inner peripheral side of the metal piece may be provided, either before the step (c) or before the step (f).
  • a step of enlarging the tip of the boss portion from the base portion may be further provided.
  • the metal piece may be provided with a main body portion and an outer peripheral portion formed stepwise, and after the step (c) or before (f), the main body portion and the outer peripheral portion may be provided.
  • a step of forming an engagement piece protruding toward the main body may be provided at the step between them.
  • an apparatus for manufacturing a flat commutator according to the present invention includes a holder formed in a disk shape of a synthetic resin, and a plurality of segments disposed along one end surface of the holder in an axial direction along a circumferential direction.
  • An apparatus for manufacturing a flat commutator comprising: a metal piece mounting portion for accommodating a chain of a plurality of metal pieces forming the segment in a circle, and mounting the metal piece; A rotating body formed in a disk shape including an inner diameter guide portion for regulating the inner circumference of the metal piece; and an outer diameter guide disposed along the outer circumference of the rotating body and regulating the outer circumference of the metal piece.
  • a chain body in which a plurality of metal pieces are continuously arranged is accommodated in a rotating body by a progressive press device or the like, and is placed between an outer diameter guide member and an inner diameter guide portion in a radial direction.
  • the chain is rounded to form a disc-shaped aggregate.
  • the flat commutator manufacturing apparatus of the present invention comprises: a holder formed in a disk shape by using a synthetic resin; and a plurality of holders arranged along one end face of the holder in the axial direction along the circumferential direction.
  • An apparatus for manufacturing a flat commutator having segments comprising: a projection which is mounted on a brush sliding surface of a metal piece forming the segment and which fits into a gap formed between the metal pieces.
  • An apparatus for manufacturing a flat commutator comprising: a cartridge; and pressing means for pressing the vicinity of the gap between the metal pieces mounted on the cartridge from a side opposite to the brush sliding surface.
  • both sides of the gap forming the slit disposed between the segments of the commutator adhere to the protrusions inserted into the gap by the pressing by the pressing means. This makes it possible to perform molding with the gap between the metal pieces being in close contact with the projections, thereby preventing the occurrence of resin burrs in the slits and improving the accuracy of slit dimensions.
  • a curved surface portion that abuts on an edge of the metal piece may be provided on the protrusion base of the cartridge.
  • the edge facing the gap of the metal piece abuts on the curved surface portion. Is deformed following the curved surface portion to form a curved surface. For this reason, when performing the cutting finish on the brush sliding surface, it is possible to suppress the occurrence of paris in the slit of the segment even if the intermittent cutting is performed. Therefore, it is not necessary to remove burrs after cutting, and it is possible to reduce the number of man-hours for commutator production.
  • the radius of the curved surface portion may be larger than a cutting allowance in a finishing surface to be applied to a brush sliding surface of the metal piece, thereby generating burrs at the time of finish cutting. Can be reliably suppressed.
  • the tip portion of the protrusion may be formed to be larger than the base portion, whereby the adhesion between the protrusion and the side surface of the gap can be improved.
  • the apparatus for manufacturing a flat commutator of the present invention includes: a holder formed of a synthetic resin in a disk shape; and a plurality of segments disposed along one circumferential direction on one axial end surface of the holder.
  • An apparatus for manufacturing a flat commutator comprising: a projection which is mounted on a brush sliding surface side of a metal piece forming the segment and which fits into a coil mounting groove formed on an outer peripheral portion of the metal piece. And a pressing means for pressing the coil mounting groove of the metal piece mounted on the cartridge from the side opposite to the brush sliding surface.
  • both sides of the coil mounting groove are brought into close contact with the projections inserted into the groove by the pressing by the pressing means. This makes it possible to perform molding with the coil mounting groove in close contact with the projection, thereby preventing resin burrs from being generated in the coil mounting groove and improving the accuracy of the groove dimension.
  • FIG. 1 is a partially cutaway perspective view showing an example of a flat commutator manufactured by a manufacturing method according to the present invention.
  • FIG. 2 is a chart showing a manufacturing process of an armature assembly using a flat commutator according to an embodiment of the present invention.
  • FIG. 3 (a) is a front view showing the structure of the chain formed in the chain forming step
  • FIG. 3 (b) is a cross-sectional view along the line AA.
  • FIG. 4 is an explanatory view showing a process of processing a chain.
  • FIG. 5 is a plan view showing a configuration of a metal piece assembling apparatus used in a chain rounding process.
  • FIG. 6 is a sectional view taken along line AA of FIG.
  • FIG. 7 is a cross-sectional view taken along the line OB of FIG.
  • FIG. 8 is an explanatory diagram showing a processing step in the chain body rounding step, and shows a state where the chain body is going to be mounted on the rotating body.
  • FIG. 9 is an explanatory diagram showing a machining process following FIG. 8 in the chain body rounding step, and shows a state where the chain body is mounted on a rotating body.
  • FIG. 10 is an explanatory view showing a machining process subsequent to FIG. 9 in the chain rounding process, in which the chain is assembled into a circle, (a) is a plan view thereof, and (b) is a plan view thereof.
  • FIG. 3A is a cross-sectional view along the line O-C.
  • FIG. 11 is an explanatory diagram showing a processing step following the step shown in FIG. 10 in the chain rounding step, and shows a state where the chain has been assembled into a circle.
  • FIG. 12 is an explanatory diagram showing a processing step subsequent to FIG. 11 in the chain body rounding step, and shows a state in which the assembly is taken out.
  • FIG. 13 (a) is a cross-sectional view showing the configuration of the cartridge
  • FIG. 13 (b) is a partial perspective view thereof.
  • FIG. 14 is an explanatory diagram showing a processing state in a burring / anchor pushing step.
  • FIG. 15 is an explanatory view showing the state of the anchor pushing protrusion and the gap in the parling / anchor pushing step.
  • FIG. 16 is a plan view showing the state of the assembly after the burring and anchor pushing steps.
  • FIG. 17 is an explanatory diagram showing a processing state in the boss taper pressing step.
  • FIG. 18 (a) is a plan view showing the state of the assembly after the boss taper pressing step
  • FIG. 18 (b) is a sectional view thereof.
  • FIG. 19 is an explanatory diagram showing a processing state in the engagement piece forming step.
  • FIG. 20 (a) is a plan view showing the state of the assembly after the engagement piece forming step.
  • FIG. 21 is an explanatory view showing a processing state in the engagement piece forming step.
  • FIG. 22 (a) is a plan view showing a state of the assembly after the engagement piece forming step
  • FIG. 22 (b) is a sectional view thereof.
  • FIG. 23 is an explanatory view showing a processing state when the carrier is removed after the molding.
  • FIG. 24 is an explanatory view showing a processing state in the coil mounting groove correcting step.
  • FIG. 25 is an explanatory diagram showing a processing state in the synthetic resin molding step.
  • FIG. 1 is a partially cut perspective view showing an example of a flat commutator manufactured by a manufacturing method according to the present invention.
  • the commutator 1 has a flat structure as shown in FIG. 1, and is used for a starter motor, an in-tank type fuel supply pump, and the like.
  • the commutator 1 includes a holder 2 made of a synthetic resin and a plurality of metal segments 3, and the segment 3 is molded integrally with the holder 2.
  • the surface of the segment 3 (the upper surface in FIG. 3) is a brush sliding surface 4, where a brush (not shown) comes in contact with the brush from the axial direction.
  • the holder portion 2 is formed in a thick, substantially disk-shaped shape, and a shaft hole 5 for fixing a motor rotation shaft is formed in a center portion.
  • a plurality of segments 3 are arranged at equal intervals on one axial end surface of the holder 2.
  • Each segment 3 is formed in a substantially sector shape, and is radially arranged on the surface of the holder 2. Further, between the segments 3, a slit 6 for electrically insulating the adjacent segments 3 from each other is formed.
  • the segment 3 has a main body 7 on which the brush sliding surface 4 is formed, and an outer peripheral portion 8 formed with a step outside the main body 7 ′.
  • a tapered boss portion 9 whose front end portion is enlarged toward the outer peripheral side is provided on the inner peripheral side of the main body portion 7.
  • an engagement piece 11 protruding toward the inner peripheral side is provided on a step portion 10 formed at a boundary between the main body 7 and the outer peripheral portion 8.
  • These bosses 9 and engagement pieces 1 1 Is a stopper for the holder 2 so that the segment 3 does not drop off in the axial direction from the holder 2 made of synthetic resin.
  • the outer peripheral portion 8 is provided with a U-shaped coil mounting groove 12.
  • An armature coil (not shown) is fixed to the coil mounting groove 12 by fusing or the like.
  • FIG. 2 is a chart showing a process of manufacturing an armature assembly using the commutator 1, and the process of manufacturing a flat commutator according to an embodiment of the present invention is applied to the processes P1 to P9. Is done.
  • an outline of the entire process will be described, and then each process according to the present invention will be described in detail.
  • the commutator manufacturing method consists of nine steps from P1 to P9 as shown in Fig. 2.
  • a chain of multiple metal pieces is rolled to create a prototype of segment 3, which is mounted on a cartridge.
  • the commutator 1 of FIG. 1 is formed by cutting and molding in the state as described above. That is, first, in step P1, a chain body in which a plurality of metal pieces forming the segment 3 are connected in series is formed. Next, this chain is assembled in a circular shape, and metal pieces are arranged along the circumferential direction (step P 2). Then, a cartridge is mounted on the circular chain (process P 3).
  • This cartridge is provided with a projection that fits into the gap formed between the metal pieces to form the slit 6, and a projection that fits in the coil mounting groove 12 and remains as it is until the final molding step P9 used.
  • a burring process for forming the boss portion 9 is performed, and at the same time, the vicinity of the gap is pressed to bring the gap into close contact with the projection (step P4).
  • the boss 9 is formed, its tip is made larger in diameter than the base (step P5), and the engaging piece 11 is formed (step P6). Thereafter, the chain is separated into individual metal pieces (step P7), and the vicinity of the coil mounting groove 12 is pressed to bring the coil mounting groove 12 into close contact with the projection (step P8).
  • the metal piece is integrally molded with synthetic resin (P 9), and the commutator 1 as shown in FIG. 1 is completed.
  • the commutator 1 completed in this way is assembled together with a rotating shaft armature core and a coil winding (not shown), and then coated with a synthetic resin to form an armature assembly (P10).
  • the brush sliding surface 4 is cleaned, and the flatness and the surface roughness are reduced. Cutting finish is performed to finish the finished product to the precision of the finished product (P ll).
  • FIG. 3 (a) is a front view showing the structure of the chain 21 formed in the process P1
  • FIG. 3 (b) is a side view thereof.
  • the chain 21 has a configuration in which a plurality of metal pieces 22 that later form the segments 3 are arranged in parallel, and are formed by a progressive press device.
  • the metal pieces 22 are formed in a semi-chain according to the number of segments, and the metal pieces 22 are connected by the carrier 23. In FIG. 3, 31 metal pieces 22 are provided, but the number is appropriately selected according to the number of segments.
  • FIG. 4 is an explanatory diagram showing a process of processing the chain 21.
  • the machined part is indicated by diagonal lines, in which a strip-shaped metal plate 24 is connected by two punching steps, two bending steps, one punching step, and one pulling-down. Molded into 1.
  • the vicinity of the carrier 23 is formed in the former punching step, and the step portion 10 is formed in the bending step.
  • the main body 7 is formed in a subsequent punching step, and is finally cut by a predetermined number (31 in this embodiment) of metal pieces 22.
  • a processing speed is high and a product having high product accuracy can be obtained with a high yield.
  • FIG. 5 is a plan view showing the configuration of the metal piece assembling apparatus used in process P2
  • FIG. 6 is a cross-sectional view taken along the line A—A in FIG. 5
  • FIG. 7 is a view taken along the line OB in FIG. FIG.
  • the metal piece assembling device 25 includes a rotating body 26 that accommodates the chained bodies 21 while collecting them in a circular shape, and an outer diameter guide disposed outside the rotating body 26. It comprises a member 27 and a knockout jig 28 for removing the chain 21 from the device.
  • a metal piece mounting portion 31 to which one metal piece 22 located at the end of the chain 21 is mounted.
  • two V'-shaped blades 32 arranged in a V-shape according to the shape of the metal piece 22 are erected as shown in FIG.
  • an inner diameter guide portion 33 for regulating the inner periphery of the metal piece 22 is provided at the center of the rotating body 26.
  • the disk 29 has a plurality of pin holes 34 in accordance with the number of the metal pieces 22.
  • the pin holes 34 are provided at positions corresponding to the main body 7 of the metal pieces 22.
  • the pin holes 34 correspond to the number of the metal pieces 22 at an equal pitch from the center between the blades 32 (31). It is formed through the disc 29.
  • An outer diameter guide member 27 is provided outside the rotating body 26 along the outer periphery of the disk 29.
  • the inner peripheral surface 27 a of the outer diameter guide member 27 has the same diameter as the circumscribed circle diameter formed by the outer peripheral portion of the metal piece 22 when the chain body 21 is assembled circularly on the disk 29. Or it is formed in a slightly large diameter.
  • the metal pieces 22 are assembled in a circular shape on the disk 29 while the outer peripheral portion is regulated by the inner peripheral surface 27a.
  • a knockout jig 28 is disposed below the rotating body 26 so as to be vertically movable.
  • the knockout jig 28 rotates together with the rotating body 26, and a plurality (31) of knockout bins 35 inserted into the pin holes 34 are provided on the upper surface thereof. .
  • the knockout pin 35 protrudes from the upper surface of the disk 29, so that the chain 21 can be pushed upward from the disk 29.
  • FIG. 8 to FIG. 12 are explanatory views showing the processing steps in the chain body rounding step P2.
  • the metal piece 22 at the end of the chain 21 is attached to the metal piece mounting portion 31. That is, as shown in FIG. 8, a metal piece 22 is inserted between the blades 32.
  • a part of the outer diameter guide member 27 is cut out so that the metal piece 22 can be easily attached to the metal piece mounting portion 31.
  • the rotating body 26 is rotated.
  • the chain body 21 is drawn into the outer diameter guide member 27 as shown in FIG. 10 while being restricted by the inner diameter guide portion 33 and the outer diameter guide member 27. .
  • the rotating body 26 is rotated once, as shown in FIG. 11, the chained body 21 is assembled in a circle, and an assembled body 36 in which the metal pieces 22 are arranged radially is formed.
  • the knockout jig 28 is moved upward, the knockout pin 35 protrudes from the upper surface of the disk 29, as shown in FIG. 12, and the assembly 36 on the disk 29 becomes a metal piece.
  • the prototype of the segment 3 can be formed only by the molding of the chain 21 and the rounding process of assembling it into a circle. Therefore, the number of steps can be significantly reduced as compared with the method of inserting the commutator pad into the cartridge as described above and the method of individually forming the segments 3 by cold forging.
  • the chain 21 is formed with high precision by a progressive press machine, man-hours can be reduced while maintaining the same accuracy as that of the cold forging method, and a highly reliable product can be manufactured at low cost. Can be manufactured.
  • FIG. 13 (a) is a cross-sectional view showing the configuration of the cartridge 37
  • FIG. 13 (b) is a partial perspective view thereof.
  • the cartridge 37 is formed in a ring shape, and as shown in Fig. 13 (a), the main body ring 37b, the outer peripheral ring 37c, and the spacer ring 37d are mounted on the base plate 37a. It is configured to be placed.
  • the main body ring 37 b is fixed on the base plate 37 a with a bolt 38, and an outer peripheral ring 37 c and a spacer ring 37 d are mounted around the body ring 37 b.
  • the upper surface of the main body ring 37b is fitted into a gap 39 'formed between the metal pieces 22 of the assembly 36 and subsequently forming the slit 6.
  • the mating protrusions 41 first protrusions
  • a projection 42 is formed on the upper surface of the outer peripheral ring 37c so as to fit into the coil mounting groove 12 formed in the metal piece 22. Then, the cartridge 37 is attached to the brush sliding surface 4 side of the assembly 36 (the lower surface side of the assembly 36 in FIG. 13), and the process proceeds to the next burring and anchor pushing step P4.
  • FIG. 14 is an explanatory diagram showing a processing state in a pearling / anchor pushing process.
  • This burring 'anchor pressing step P4 to the coil mounting groove correcting step P8 are performed by a press device, and in this step, the assembly 36 is placed on the stocker 43 together with the cartridge 37.
  • a punch holder 44 is provided below the stopper 43, and a burring punch 45 is erected in the center thereof.
  • the tip of the burring punch 45 has a guide portion inserted into the inner periphery of the assembly 36. 45 a and a punch portion 45 b for forming the post portion 9 are provided.
  • a spring 46 and a torsion plate 47 are provided between the punch holder 44 and the stopper 43. The punch holder 44 can be moved upward until the butting plate 47 contacts the stopper 43. After the movement, the punch holder 44 returns to the state shown in FIG.
  • a burring die 48 is arranged on the upper surface side of the assembly 36.
  • An anchor pushing protrusion 49 is provided on a surface (the lower surface in FIG. 13) of the perling die 48 facing the assembly 36.
  • the anchor push projection 49 is provided 31 in correspondence with the gap 39 of the assembly 36, and is formed wider than the gap 39.
  • the cart ridge 37 is attached to the stopper 43 with the anchor pushing protrusion 49 positioned so that the gap 39 is opposed to the gap 39.
  • the perling punch 45 When the punch holder 44 moves upward in the drawing in such a press device, the perling punch 45 also moves upward accordingly.
  • the perling punch 45 abuts the assembly 36 whose upward movement is restricted by the parling die 48, and the punch portion 45 b pushes up the center of the assembly 36.
  • a boss 9 extending along the central axis protrudes from the center of the assembly 36.
  • FIG. 15 is an explanatory view showing a state of the anchor pushing protrusion 49 and the gap 39 at the time of the step P4, and FIG. 16 is a plan view showing a state of the assembly 36 'after the burring / anchor pushing step.
  • the anchor pushing projection 49 is pushed into the vicinity from above the gap 39, and the upper surface of the metal piece 22 has an anchor mark 5 as shown in FIG. 1 is formed. Further, at this time, the side surfaces of the gap 39 located therebelow are deformed by the pressing by the anchor pressing projection 49 so as to swell into the gap.
  • the projections 41 are inserted into the gaps 39, whereby both side surfaces of the gaps 39 are pressed against the projections 41 of the cartridge 37, and the projections 41 in the gaps 39 are formed.
  • the end face of the metal piece 22 comes into close contact with the metal piece.
  • the synthetic resin does not enter the gap 39 in the molding step P9 described later, and the portion of the protrusion 41 remains as a concave portion between the segments 3 as it is. And this The recessed portion becomes the slit 6 as it is.
  • the commutator 1 can omit the slit cutting after the mold forming, and can reduce the number of man-hours.
  • the slit 6 is formed by the projection 41 of the cartridge 37, the slit position accuracy can be improved as compared with the slit formation by the blade, and the variation in the product accuracy can be reduced.
  • the protrusion 41 may have not only a straight shape as shown in FIG. 15 but also an inverted tapered shape in which a tip portion is larger than a base portion in order to improve adhesion.
  • the projection 41 has a curved surface 52 at the base thereof.
  • the curved surface portion 52 comes into contact with an edge 53 facing the gap 39 of the metal piece 22.
  • the anchor pushing protrusion 49 is pressed in the vicinity of the gap 39 in each state, the end edge 53 is deformed following the curved surface portion 52. That is, a curved surface (R) is formed in the segment 3 such that the curved surface portion 52 is transferred to the corner facing the slit 6.
  • the brush sliding surface 4 of the commutator 1 is cut and finished after the molding. During this finish cutting, burrs are generated in the slit, and in the conventional commutator, they are removed later by puffing.
  • the entrance of the slit 6 is a curved surface, even if the intermittent cutting is performed, the generation of the spar in the slit 6 can be suppressed.
  • the radius of the curved portion 52 is set to be larger than the cutting allowance in the finish machining, and the finish cutting is performed within the range of the curved portion 52.
  • FIG. 17 is an explanatory view showing the processing state in the boss taper pressing step
  • FIG. 18 (a) is a plan view showing the state of the assembly 36 after the boss taper pressing step
  • (b) is a cross-sectional view thereof It is.
  • the cartridge 37 is placed on the torso block 54.
  • the center of this torso block 5 4 Is provided with a trunk projection 54 a inserted into the inner periphery of the cartridge 37.
  • a stripper 55 is disposed above the assembly 36.
  • a punch holder 57 is disposed above the stripper 55 via a spring 56.
  • a punch 58 protruding downward is attached to the punch holder 57.
  • the tip of the punch 58 has a tapered portion 58a, and the tip of the tapered portion 58a has substantially the same diameter as the inner diameter of the boss 9 currently formed.
  • the base side (upper side in FIG. 17) of the taper section 58 a is formed to have a larger diameter than the inner diameter of the boss section 9.
  • the punch 58 is lowered accordingly. At this time, a punch 58 is inserted into the boss 9 of the assembly 36, and the tapered portion 58 a contacts the inner periphery of the boss 9.
  • the taper portion 58a is inserted into the boss portion 9, and the boss portion 9 is expanded in diameter along the taper portion 58a.
  • the punch 58 is lowered until it comes into contact with the lug ⁇ 54 a of the torsion block 54, thereby increasing the diameter of the boss 9 at the tip end side from the base side, as shown in FIG. 17.
  • Tapered shape In this case, the tapered boss portion 9 is embedded in the holder portion 2 in an anchor shape as shown in FIG. 1 when the metal piece 22 is molded to form the holder portion 2 and the segment 3 comes off. Acts as a stop.
  • FIG. 19 is an explanatory view showing a processing state in the engaging piece forming step
  • FIG. 20 (a) is a plan view showing a state of the assembly 36 after the engaging piece forming step
  • (b) is a sectional view thereof. It is.
  • a stripper 59 is disposed above the assembly 36 here.
  • a punch holder 62 is disposed via a spring 61.
  • a punch 63 projecting downward is attached to the punch holder 62.
  • a nail shaving portion 63 a is formed at the tip of the punch 63.
  • the outer diameter of the nail shaving part 63 a is formed slightly smaller than the inner diameter of the step part 10.
  • the inner peripheral side of the nail shaving portion 63a has a tapered shape whose diameter is increased upward.
  • the punch holder 62 When the punch holder 62 is lowered in the apparatus shown in FIG. The punch 63 descends, and the nail shaving part 63 a of the punch 58 contacts the upper surface of the step part 10. Further, when the punch 63 is further lowered by a dimension not exceeding the height of the step portion 10, the nail shaving portion 63a bites into the step portion 10, and an engagement piece 11 is formed on the inner peripheral side thereof. Is done. At this time, the engaging piece 11 is formed so as to protrude toward the inner peripheral side along the tapered shape of the nail shaving portion 63a. The engagement piece 11 protruding inward is embedded in the holder 2 as an anchor when the metal piece 22 is molded to form the holder 2 as shown in FIG.
  • the tapered boss 9 functions as a stopper for the segment 3.
  • FIG. 21 is an explanatory view showing a processing state in the engagement piece forming step
  • FIG. 22 (a) is a plan view showing a state of the assembly 36 after the engagement piece formation step
  • (b) is a sectional view thereof. is there.
  • a trim die 64 and a knockout block 65 are arranged above the assembly 36.
  • the trim die 64 is arranged at the portion of the carrier 23, and the knock art block 65 is arranged inside the trim die 64.
  • the outer peripheral ring 37 c of the cartridge 37 is used as a trim punch 66. This eliminates the need to provide a separate punch member, simplifies the mold configuration, and reduces production costs.
  • the carrier 23 is cut between the trim die 64 and the trim punch 66 accordingly. At this time, the metal pieces 22 are separated from each other. However, since the metal pieces 22 are housed in the cartridge 37 and the movement thereof is regulated by the projections 41 and 42, the carrier 23 may not be separated by cutting. Absent. Then, after cutting the carrier 23, the knockout block 65 is lowered, so that the assembly 36 that has entered the trim die 64 is removed.
  • a method of cutting off the molding after molding may be considered.
  • the cutting is performed intermittently including the coil mounting groove 12
  • the tool is greatly damaged and the manufacturing cost is increased.
  • burrs are likely to be generated in the coil mounting groove 12 in the circumferential direction, and if the burrs are generated in the groove, the coil is difficult to insert, which may cause a winding defect.
  • the commutator manufacturing method focuses on mounting the cartridge 37 and performing press working at P 4 to P 6, and cutting the carrier 23 by press working before the molding step, as described above. Is trying to solve various problems. This eliminates the need for cutting work after molding, reducing man-hours, and preventing circumferential burrs and preventing damage to the synthetic resin, thereby improving product reliability. '
  • the dimension of the coin mounting groove 12 is corrected before molding (step P 8).
  • the groove processing accuracy tends to vary.
  • the cartridge 37 is provided with a projection 42 that fits into the coil mounting groove 12 to prevent resin from entering the groove. .
  • the metal piece 22 that has passed through the press processing of P4 to P7 changes the dimensions of the coil mounting groove 12 due to the effects of other processing steps, There may be gaps.
  • the resin may flow into the groove from the gap and resin burrs may be generated. Therefore, immediately before the molding step, a step of adhering the coil mounting groove 12 to the protrusion 42 is provided to correct the dimensions of the coil mounting groove 12 and prevent burrs.
  • FIG. 24 is an explanatory view showing a processing state in the coil mounting groove correcting step.
  • Figure 2 As shown in FIG. 4, here, a compression punch 67 is arranged above the assembly 36, and is pressed against the vicinity of the coil mounting groove 12 from the upper surface side of the metal piece 22. The pressing by the compression punch 67 deforms both side surfaces of the coil mounting groove 12 so as to swell into the groove. In this case, the protrusions 42 are inserted into the coil mounting grooves 12, whereby both side surfaces of the coil mounting grooves 12 are pressed against the protrusions 42, and the protrusions 42 are formed in the coil mounting grooves 1. Adhere to 2.
  • the coil mounting groove 12 can be formed at the same time when the chain 21 is formed, and the number of steps can be significantly reduced as compared with the case where the groove is formed later by cutting. Furthermore, by making the coil mounting groove 12 closely contact the projection 42, the dimension and shape of the groove are corrected according to the projection 42, so that the dimensional accuracy of the coil mounting groove 12 is smaller than that of cutting. Thus, it is possible to prevent coil insertion failure during winding.
  • FIG. 25 is an explanatory view showing a processing state in the synthetic resin molding step.
  • the metal piece 22 is again processed while being mounted on the cartridge 37, and the cartridge 37 is housed in the lower mold 69 in which the center pin 68 is planted.
  • a gate plate 73 having a gate 71 is disposed above the cartridge 37.
  • a synthetic resin is injected from the gate 71, and after it is solidified, the molded product is taken out together with the cartridge 37 by the ezieto pin 72.
  • the finished molded product can be processed with the protrusions 42, 42 of the cartridge 37 and the P4, P8 process, etc., to eliminate the resin leakage and obtain a highly accurate product. .
  • the cartridge 37 After molding with synthetic resin, the cartridge 37 is removed from the molded product, and the commutator 1 as shown in Fig. 1 is completed. The cartridge 37 can be reused thereafter.
  • the commutator 1 completed in this way is assembled together with a rotating shaft armature core, coil windings and the like (not shown), and then a synthetic resin coating is applied to form an armature assembly (P 1 0).
  • the commutator 1 is exposed to a high temperature of about 150 to 180 degrees at the time of coating with a synthetic resin, the copper segment 3 is oxidized and discolored. For this reason, after the assembly process P10, the brush sliding surface 4 is cleaned, and a cutting finish is performed to finish the flatness and surface roughness to the accuracy of the finished product (Pll).
  • the slits 6 and coil mounting grooves 12 are formed with high precision by the projections 41 and 42, and the processing after molding only requires finishing of the brush sliding surface 4, which is similar to a conventional commutator. No slitting is required. For this reason, commutator manufacturing man-hours can be significantly reduced, and product accuracy is improved, thereby reducing costs and improving reliability.
  • the manufacturing method of the present invention has been described by taking a commutator having 31 segments as an example, but the number is not limited to 31 and may be changed according to the specifications of the rotating electric machine. It can be changed as appropriate.
  • P5 must be set after P4 and P8 must be set immediately before P9, but P6 and P7 need not be set after P5. It is also possible to reverse the order of P6 and P7. That is, the processing can be performed in the order of P3 ⁇ P7 ⁇ P6 ⁇ P4 ⁇ P5 ⁇ P8 ⁇ P9.
  • the processes of P4 and P8 are also effective in the case where individual metal pieces are accommodated in a cartridge and processed without using a chain. That is, the metal pieces 22 press-molded as a single item are arranged in the cartridge 37, The processing of P4 and P8 can be applied also when forming data.
  • the burring / anchor pushing process P4 two processes of the pearling and the anchor pushing are performed in one process, but these processes can also be performed in independent processes.
  • the flat piece commutator is obtained by forming the chain which connected the several metal piece which forms a segment, forming it circularly, and molding this with a synthetic resin.
  • the metal pieces that are continuously provided are separated into individual metal pieces before molding, there is no need to perform a cutting process for separating the metal pieces after molding. Therefore, it is possible to reduce man-hours and to prevent the occurrence of burrs in the circumferential direction during processing and to prevent damage to the synthetic resin, thereby improving product reliability.
  • a cartridge provided with a projection that fits into a gap formed between the metal pieces is attached to the metal piece forming the segment, and the metal piece near the gap between the metal pieces is provided. Since the mold is molded after the gap is pressed against the projection by pressing the resin, the synthetic resin does not enter the gap during molding, and the projection remains as a recess between the metal pieces to form a slit. For this reason, the slit force processing after the mold molding can be omitted, and the man-hour can be reduced. In addition, since the slit is formed by the projection of the cartridge, the slit position accuracy can be improved as compared with the slit formation by the blade, and the variation in product accuracy can be reduced.
  • a metal member forming a segment is provided with a cartridge provided with a projection that fits into a coil mounting groove formed on an outer peripheral portion of the metal member, Molding is performed after pressing the coil mounting groove on the protrusion by pressing the coil mounting groove near one side, so that synthetic resin does not enter the coil mounting groove at the time of molding and resin spar occurs in the groove Can be prevented. Because of this, the resin burr problem in the groove is solved, At the same time, a coil mounting groove can be formed at the same time, and the number of steps can be significantly reduced as compared with a case where a groove is formed later by cutting.
  • the dimensions and shape of the groove are corrected according to the protrusion, so that the dimensional accuracy of the coil mounting groove can be improved as compared with the cutting process. This makes it possible to prevent poor coil insertion.
  • a cartridge which is mounted on a brush sliding surface side of a metal piece forming a segment and has a projection which fits into a gap formed between the metal pieces; Since the pressing means for pressing the vicinity of the gap between the metal pieces mounted on the cartridge is provided, both sides of the gap can be brought into close contact with the projection by the pressing by the pressing means. Accordingly, it is possible to perform molding with the gap between the metal pieces being in close contact with the protrusions, thereby preventing the occurrence of resin spar in the slit and improving the accuracy of the slit dimension.
  • the projection is inserted into the gap, and when the vicinity of the gap is pressed in this state, the edge of the metal piece facing the gap becomes a curved surface.
  • a curved surface is formed by deforming according to the part, and when cutting the brush sliding surface, it is possible to suppress the generation of burrs in the slits of the segments even when performing intermittent cutting. Therefore, it is not necessary to remove the paris after cutting, and it is possible to reduce the number of man-hours for manufacturing commutator. In this case, by making the radius of the curved surface portion larger than the cutting allowance at the time of finishing, the occurrence of burrs at the time of finish cutting can be surely suppressed.
  • the projection is mounted on the brush sliding surface side of the metal piece forming the segment and fits into the coil mounting groove formed on the outer peripheral portion of the metal piece.
  • the pressing means for pressing the metal piece mounted on the cartridge in the vicinity of the coil mounting groove are provided, so that both sides of the coil mounting groove can be brought into close contact with the projections by pressing by the pressing means. This makes it possible to perform molding with the coil mounting groove in close contact with the protrusion, thereby preventing resin burrs from being generated in the coil mounting groove and improving the groove dimension accuracy.

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

Abstract

L'invention concerne un procédé de fabrication d'un commutateur plat possédant plusieurs segments disposés au niveau d'une section de maintien en résine synthétique dans le sens périphérique. Ce procédé comprend l'étape P1 de formation d'un corps de chaîne constitué de plusieurs pièces métalliques, l'étape P2 d'assemblage du corps de chaîne de façon circulaire, l'étape P3 de fixation d'une cartouche possédant un premier ergot logé dans le trou entre les pièces métalliques et un second ergot logé dans une rainure de fixation de la bobine au corps de chaîne, l'étape P4 d'application du trou entre les pièces métalliques étroitement par rapport au premier ergot par pressage de la proximité du trou, l'étape P7 de séparation des pièces métalliques de façon individuelle, l'étape P8 d'application de la rainure de fixation de bobine étroitement par rapport au second ergot par pressage de la proximité de la rainure, et l'étape P9 de moulage des pièces métalliques de façon intégrale au moyen de résine synthétique avec la cartouche y étant fixée.
PCT/JP2002/011218 2001-12-11 2002-10-29 Procede de fabrication d'un commutateur plat et systeme de fabrication correspondant WO2003050932A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2002344597A AU2002344597A1 (en) 2001-12-11 2002-10-29 Method for manufacturing flat commutator and its manufacturing system
JP2003551883A JP4230358B2 (ja) 2001-12-11 2002-10-29 偏平型コンミテータの製造方法及びその製造装置

Applications Claiming Priority (2)

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JP2001-377943 2001-12-11
JP2001377943 2001-12-11

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WO2003050932A1 true WO2003050932A1 (fr) 2003-06-19

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CN (1) CN1331301C (fr)
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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2009131095A (ja) * 2007-11-27 2009-06-11 Mitsuba Corp 扁平型コミュテータ及びその製造方法
JP2009131096A (ja) * 2007-11-27 2009-06-11 Mitsuba Corp 扁平型コミュテータの製造方法
JP2009131094A (ja) * 2007-11-27 2009-06-11 Mitsuba Corp 扁平型コミュテータの製造方法
US7551463B2 (en) 2004-05-11 2009-06-23 Thales AC/DC converter with low harmonic currents

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1330060C (zh) * 2005-04-22 2007-08-01 陈阿陆 端面换向器的制造方法
CN101860128B (zh) * 2010-05-11 2012-06-20 温州科奇比威自动化设备有限公司 换向片组合分度旋转机构

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JPS347814B1 (fr) * 1958-09-10 1959-09-05
JPS4916801A (fr) * 1972-06-09 1974-02-14
JPH0279751A (ja) * 1988-09-16 1990-03-20 Sugiyama Seisakusho:Kk 平型整流子およびその製造方法
JPH0386040A (ja) * 1989-08-29 1991-04-11 Aisan Ind Co Ltd 整流子及びその製造方法

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Publication number Priority date Publication date Assignee Title
EP0393685A1 (fr) * 1989-04-20 1990-10-24 Kawasaki Steel Corporation Copolymères à groupements imides et leurs utilisations

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Publication number Priority date Publication date Assignee Title
JPS347814B1 (fr) * 1958-09-10 1959-09-05
JPS4916801A (fr) * 1972-06-09 1974-02-14
JPH0279751A (ja) * 1988-09-16 1990-03-20 Sugiyama Seisakusho:Kk 平型整流子およびその製造方法
JPH0386040A (ja) * 1989-08-29 1991-04-11 Aisan Ind Co Ltd 整流子及びその製造方法

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7551463B2 (en) 2004-05-11 2009-06-23 Thales AC/DC converter with low harmonic currents
JP2009131095A (ja) * 2007-11-27 2009-06-11 Mitsuba Corp 扁平型コミュテータ及びその製造方法
JP2009131096A (ja) * 2007-11-27 2009-06-11 Mitsuba Corp 扁平型コミュテータの製造方法
JP2009131094A (ja) * 2007-11-27 2009-06-11 Mitsuba Corp 扁平型コミュテータの製造方法

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JPWO2003050932A1 (ja) 2005-04-21
CN1331301C (zh) 2007-08-08
JP4230358B2 (ja) 2009-02-25
CN1602574A (zh) 2005-03-30
AU2002344597A1 (en) 2003-06-23

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