WO2013087441A1 - Moteur électrique et procédé de fabrication d'un moteur électrique - Google Patents

Moteur électrique et procédé de fabrication d'un moteur électrique Download PDF

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Publication number
WO2013087441A1
WO2013087441A1 PCT/EP2012/074256 EP2012074256W WO2013087441A1 WO 2013087441 A1 WO2013087441 A1 WO 2013087441A1 EP 2012074256 W EP2012074256 W EP 2012074256W WO 2013087441 A1 WO2013087441 A1 WO 2013087441A1
Authority
WO
WIPO (PCT)
Prior art keywords
wire ends
commutator
pressing member
pressing
contact points
Prior art date
Application number
PCT/EP2012/074256
Other languages
German (de)
English (en)
Inventor
Friedhelm Guenter
Reiner Ramsayer
Original Assignee
Robert Bosch Gmbh
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 Robert Bosch Gmbh filed Critical Robert Bosch Gmbh
Publication of WO2013087441A1 publication Critical patent/WO2013087441A1/fr

Links

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
    • 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

Definitions

  • the invention relates to an electric machine, in particular a generator or a starting device such as a starter for starting an internal combustion engine, according to the preamble of claim 1.
  • the invention relates to a method for producing an electrical machine, in particular a generator or a starter device for starting an internal combustion engine, according to the preamble of claim 4.
  • the invention is based on a system with an electric machine such as a generator, starter or a starter motor according to the preamble of the independent claims.
  • the present invention relates to electrical machines, in particular
  • Generators, starters and starters for vehicles with internal combustion engines comprising an electric machine with a commutator, which is connected to coil wires.
  • Electric machines with commutators are known from the prior art, in which an electrical contacting of the coil wires to the commutator by means of soldering, welding or other thermal joining method.
  • the electric machine according to the invention and the method according to the invention with the features of the corresponding main claim or independent claim have the advantage over the prior art that in an electric machine, in particular a generator or a starter device such as a starter for cranking an internal combustion engine comprising at least one commutator , which is electrically connected via terminals with wire ends, wherein the wire ends are pressed at the contact points via a pressing member on the commutator, any material pairings of wire ends and commutator can be used.
  • the connections of wire ends and commutator can be realized in a single step.
  • the commutator has suitable contact points.
  • the contact points are preferably formed as so-called commutator or short lamellae.
  • Such lamellae each have a groove, a slot or a lamellar groove for receiving at least one wire end at a suitable contact point, which is oriented substantially radially.
  • several lamellae for several wire ends are approximately radially aligned, provided adjacent to each other in the circumferential direction.
  • the respective stripped coil wire end is inserted.
  • Slot and wire end are each designed to match.
  • the wire end is arranged twice or more laid in the groove.
  • two or more wire ends of different wires are arranged in a groove.
  • the slot or the groove is preferably rectangular or cuboid.
  • Wire ends are preferably round or cylindrical.
  • the wire ends are arranged in the slot compressed or deformed. Accordingly, the wire ends are arranged in the slot deformed such that the wire material after compression occupies part of the space before compression, so that after compression, the free space is reduced.
  • the Protruding wire ends before pressing the pressing member in the radial direction over the slot.
  • the wire end and the blade are not flush at a radially outer edge of the blade, but the wire end protrudes with a part of its circumference beyond the blade.
  • the individual lamellae are arranged at a distance from each other.
  • the lamellae are insulated from one another.
  • an insulating compound in the circumferential direction that is, provided between the slats. So that the wire ends are fixed, in particular stationary, in the slot also during operation, they are pressed onto the commutator via a press component.
  • the press component has an inner contact surface adapted to the surface arrangement of the slats. Because the
  • Slats are arranged approximately circular, also has the pressing member on an approximately circular contact surface.
  • the pressing member is formed ring Vietnamesezylindrisch.
  • the annular pressing component is preferably made of aluminum or copper, but also on steel base, in particular spring steel base.
  • the wire ends, the contact points and / or the pressing component have an insulation.
  • both the lamellae are mutually insulated with each other and the wire ends. Between the slats, that is in
  • an insulating material is preferably provided. So that the pressing component pressed onto the lamellae does not have a conductive bridge between the lamellae and / or forms the wire ends, the wire ends and / or the inner stop surface of the pressing member are further isolated.
  • the insulation serves on the one hand to avoid short circuits. On the other hand, the insulation is advantageously formed against wear or corrosion.
  • the wire ends are at least partially coated with an insulating agent.
  • the wire ends are coated for improved electrical conduction of the electrical current to the fins.
  • a separter insulating ring between the pressing member and fins / commutator is provided.
  • the insulating ring is made of a plastic or other suitable insulating material.
  • the pressing member is preferred as
  • Metal ring formed wherein the material is designed so that this holds a material tension over its life without substantially relax and / or to flow.
  • materials are provided as a steel material, such as spring steel or another steel, or - matched to the load case - and materials such as copper, aluminum and their
  • electrically conductive materials in particular materials having suitable electromechanical properties, are preferred.
  • the insulation is embodied integrated in the press component.
  • an insulating ring is formed in and / or on the pressing member, for example as an insulating coating or as an injection molded part, which are connected to the pressing member.
  • insulation and pressing component form a composite material.
  • the pressing of the pressing member on the commutator is preferably carried out in a joining process with the electromagnetic pulse technique.
  • no other compound or joining substances, such as adhesives, welds or other fillers are needed.
  • the pressing component is around the
  • Commutator arranged, subjected to an electromagnetic pulse or a plurality of pulses and by the induced eddy currents in the pressing member, the pressing member shrinks on the commutator.
  • a further embodiment provides that the wire ends of a
  • Non-copper material in particular made of aluminum.
  • the commutator or the fins are preferably made of a copper material.
  • the commutator and / or fins are also made of other electrically conductive materials such as aluminum and the like.
  • Aluminum wire ends and copper materials are thermally very difficult to add. By the pressing member a joint connection is realized in the aluminum wire ends and Optionally use copper lamellae or other materials which are poorly suited for thermal insulation.
  • the inventive method with the features of the corresponding main claim or independent claim has the prior art over the advantage that in the manufacture of an electric machine according to the invention, in particular a generator or a starter for cranking an internal combustion engine comprising at least one commutator electrically via contact points is connected to wire ends, wherein the wire ends are pressed at the contact points via a pressing member on the commutator, can be used for the wire ends and the commutator also materials that are poor or not connectable via a thermal joining method. By pressing the pressing member is reduced at least in an internal dimension - shrunk - so that it rests stationary on the commutator.
  • the wire ends can be in a single step with the
  • the pressing component is pressed by means of a joining process with the electromagnetic pulse technique.
  • the joining process according to the electromagnetic pulse technique has the advantage that due to the high forming speed due to the short pulse duration and the high force impact, springback is minimized and a press component is permanently pressed on.
  • a further embodiment provides that before pressing the wire ends in
  • the wire ends, the contact points and / or the pressing member are isolated. In order to prevent short circuits or unwanted current flows between the wire ends and / or the fins, insulation is provided. The isolation is preferably carried out on the
  • Wire ends, the slats and / or the pressing member are coated.
  • the pressing member is coated on a side facing the wire ends.
  • walls of the fins are coated. The coating is carried out with a suitable insulating material.
  • Slats are insulated from each other by a suitable insulating compound.
  • the insulation takes place at least with regard to an electrical line. Other insulation, for example thermal insulation or the like, are feasible.
  • an embodiment provides that all wire ends are pressed together.
  • the pressing of the wire ends is done in a single joining process.
  • the annular pressing member is brought around the commutator.
  • the commutator press assembly is placed in a press tool.
  • the pressing tool acts circumferentially on the entire pressing component.
  • the pressing tool for this purpose is also annular. In its inner
  • the pressing member is arranged together with commutator. Then a pulse or a pulse acts or several pulses or pulses act on the pressing component.
  • the pressing member is compressed at least in terms of its internal dimension and shrunk onto the commutator, pressed or joined.
  • the method according to the invention can be represented as follows:
  • the method according to the invention makes it possible to produce all electrical connections on the commutator in a single joining process step, without the use of thermal joining methods.
  • the wire ends and / or the commutator contact points can be advantageously coated to protect against corrosion or to improve the electrical properties.
  • the groove in the commutator is adapted to the wire diameter in length, width and / or depth of the cross section and / or the shape of the wire end.
  • a part of the wire end still protrudes out of the groove in the commutator before the joining process.
  • mechanical forming the wire can still be compressed or compressed in the groove, so that the Wire already in the groove creates and cavities are closed or at least minimized.
  • a part of the wire is advantageous even after compression still on the groove in the commutator out.
  • an insulating ring and a press component formed as a metal ring are inserted over the commutator with the inserted wire ends.
  • the insulating ring may consist of appropriately designed plastic or other suitable insulating material.
  • the metal ring is preferably made of a material that holds the material tension over life without relaxing or flowing too fast.
  • a steel material spring steel or other steel
  • materials such
  • Copper or aluminum can be dispensed with the insulating when the insulation is provided directly, for example as a coating or as an injection molded part or the like with the metal ring.
  • a sufficiently well coated steel sheet is used. If the annular pressing component with its inner contact facing the commutator is arranged around the commutator, then this arrangement is placed in a coil and subjected to an electromagnetic pulse. In this case, in the very short time of the electromagnetic pulse (few ⁇ ) eddy currents are induced in the metal ring, which repel from the generated magnetic field of the coil and so the metal ring on the
  • the compound is virtually gas-tight and thus offers little chance of attack for corrosion, etc., which significantly reduces the risk of electrical failure of the compound (high-resistance).
  • the metal ring secures the wires at high speeds in the groove before the then prevailing high centrifugal forces. This results, among other things, in the advantages that a simple connection of wire or wires to commutators of electrical machines is realized. Preliminary work, such as treating the wire ends (except stripping) or the contact points omitted.
  • materials are to be joined, in which classical joining methods due to metallurgical or other circumstances are not suitable (for example
  • Alumium wire to Kupferkommutator the inventive method is suitable. Further advantages are that all connections can be made in one shot, the securing of the wires in the groove by a joining tool (metal ring) safely and over the lifetime haslbar, a stable connection with high bond strengths is realized and the method with little effort by short cycle times is feasible.
  • FIG. 1 shows a perspective view schematically a commutator of an electrical machine
  • FIG. 1 with a higher level of detail
  • FIG. 2b is a perspective view of a section of the commutator according to FIG. 2a
  • FIG. 3 is a schematic cross-sectional view of a detail of FIG.
  • FIG. 4 shows schematically the pressing operation before and after the pressing of the
  • the commutator includes commutator bars 54, which are arranged annular outside.
  • the commutator bars or shortly fins 54 have an outwardly, that is, radially away from a zenralen shaft 17, directed lamellar surfaces, which form a tread for commutator brushes not shown here.
  • the fins 54 each have commutator contact points 55 or short contact points 55.
  • the commutator contact points 55 are electrically connected to coil wires, more precisely to coil wire ends or short wire ends 56.
  • At the contact points 55 is used to connect the coil wire ends 56 to the commutator 53 and with the Commutator contact points 55 a pressing member (not shown here) pressed. This is shown in more detail in FIGS. 2 a, 2 b and 3.
  • FIG. 2a shows, in another perspective view, the commutator 53 according to FIG. 1 with a higher degree of detail.
  • FIG. 2b shows a perspective view of a section of the commutator according to FIG. 2a.
  • the higher level of detail clearly shows how the wire ends 56 are arranged on the commutator contact points 55.
  • the commutator 53 has fins 54 for connection to the wire ends 56.
  • the fins 54 have contact points 55.
  • the contact points 55 are formed as grooves, the one
  • the fins 54 have depression in the radial direction and are open in the axial direction.
  • the fins 54 are circumferentially equally spaced.
  • the individual fins 54 are insulated against each other by insulating materials 58.
  • two wire ends 56 of different wires are arranged in the present embodiment.
  • the wire ends 56 are in terms of shape and
  • the width of the groove that is the width in the circumferential direction, approximately corresponds to the diameter of the wire ends 56, so that here is a free space 59 between the wire ends 56 and the walls of the groove is reduced.
  • the depth of the groove that is, the depth in the radial direction, is dimensioned so that one of the wire ends 56 protrudes partially in the radial direction beyond the groove.
  • the grooves for receiving the two wire ends 56 are formed uniformly distributed in the circumferential direction, wherein in each case the wire ends 56 of two different wires are arranged in the grooves. The arrangement of the wire ends 56 of each two different wires per groove and the protruding of the wire ends 56 in the radial direction is shown more clearly in FIG.
  • FIG. 3 schematically shows, in a cross-sectional view, a detail of the commutator 53 in the region of the commutator contact points 55.
  • four are completely formed as lamellae 54
  • the fins 54 are radially aligned away from a common center M.
  • the lamellae 54 are formed in the circumferential direction U approximately equal to each other.
  • the lamellae 54 are made of a material which conducts the electrical current well, in this case copper. Between the individual fins 54 is in the circumferential direction U insulation in the form of a
  • Insulating compound 58 arranged so that the fins 54 are formed isolated from each other. At their radial outer end, the fins 54 a Slot, a groove or a lamellar groove 57 on.
  • the lamellar grooves 57 are designed to receive the wire ends 56, in this case two wire ends 56 of different wires, and are adapted to the diameter, the length and / or the depth of the wire ends 56. In the example shown, two wire ends 56 of different wires are inserted in each slat groove 57.
  • a wire end can be laid double, that is once folded or bent through 180 °, be arranged in the groove.
  • the two wire ends 56 of each groove lie approximately parallel to each other in the lamellar groove 57.
  • a part T of the respective radially outer wire end 56 protrudes partially beyond an end of the lamellar groove 57, more precisely in the radial direction R.
  • a pressing member 60 is arranged in the form of a ring.
  • Pressing member 60 is not pressed onto the commutator 53 for a better overview but shown before pressing.
  • insulation 61 is provided on the inner side contacting the wire ends 56, that is to say on an inner contact surface of the pressing component 60.
  • the insulation 61 is formed in the form of a voltage applied to the contact surface of the pressing member 60 insulating ring 61a. This is formed integrally here as a coating with the pressing member 60. In the state shown here, the pressing member 60 bears against the protruding parts T of the wire ends 56, so that there is an air gap between the fin surfaces and the pressing member 60.
  • the wires, and thus the wire ends 56 are made of a unitary material in one embodiment.
  • the wire ends 56 are made of a plurality of wire fibers, as illustrated by the honeycomb hatching of the wire ends in FIG. Basically, the wire ends 56 are made of a solid material, that is not of several Individual fibers.
  • the radially inner wire ends 56 are smaller, that is shown formed with a smaller diameter. In other embodiments, the radially inner wire ends 56 are the same size or larger than the radially outer wire ends 56 are formed. At least the radially inner wire ends 56 are preferably arranged compressed in the groove, so that the free space 59 is reduced between wire ends 56 and walls of the groove.
  • FIG. 4 schematically shows the pressing operation before and after the pressing of the pressing component 60.
  • a pressing tool 70 is moved around the
  • the pressing tool 70 comprises a coil 70a. Via the coil 70a, an (in) pulse is applied to the pressing component 60, more precisely an electromagnetic (im-) pulse.
  • the pulse duration is in the range of a few ⁇ . During the duration of the electromagnetic pulse are formed in the metal ring as
  • Pressing member 60 induces eddy currents that repel a generated magnetic field of the coil 70a.
  • the metal ring is sprinkled on the commutator 53 and formed accordingly. Due to the high acceleration, the deformation takes place at a high speed, whereby a springback-free or a nearly springback-free forming is realized. Due to this low or nonexistent springback of the metal ring, a joining force is generated which presses the wire ends 56 securely in the lamellar groove 57 and holds it there for a long time. In this case, the wire ends 56 are due to the protruding part T, which is pressed completely into the blade groove 57, compressed or compressed. As a result, any free spaces 59 are further minimized, so attack options for
  • FIG. 3 shows the state before and after the pulse.
  • the pressing member 60 is shown with a projection D with respect to the commutator 53, in which the pressing member 60 does not overlap with the commutator 53. Basically, this supernatant D is not required. It is clear in Figure 3, the deformation of the
  • the coil 70a is formed in the dargestellen embodiment as a circumferentially continuous coil 70a. In a In another embodiment, the coil 70a is formed, for example, as a radially slotted coil or composable coil.

Abstract

La présente invention concerne un moteur électrique, en particulier un générateur ou un dispositif de démarrage tel qu'un démarreur pour démarrer un moteur à combustion interne, comprenant au moins un collecteur (53) qui est relié électriquement à des extrémités de fil (56) par l'intermédiaire de points de contact (55), les extrémités de fil (56) étant pressées sur le collecteur (53) par un élément de pressage (60) aux points de contact (55). L'invention concerne également un procédé de fabrication du moteur électrique.
PCT/EP2012/074256 2011-12-15 2012-12-03 Moteur électrique et procédé de fabrication d'un moteur électrique WO2013087441A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011088697A DE102011088697A1 (de) 2011-12-15 2011-12-15 Elektrische Maschine und Verfahren zur Herstellung einer elektrischen Maschine
DE102011088697.4 2011-12-15

Publications (1)

Publication Number Publication Date
WO2013087441A1 true WO2013087441A1 (fr) 2013-06-20

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PCT/EP2012/074256 WO2013087441A1 (fr) 2011-12-15 2012-12-03 Moteur électrique et procédé de fabrication d'un moteur électrique

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WO (1) WO2013087441A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3083026A1 (fr) * 2018-06-25 2019-12-27 Valeo Equipements Electriques Moteur Procede de connexion de fils sur un collecteur de moteur electrique

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102021110073A1 (de) 2021-04-21 2022-10-27 Nidec Motors & Actuators (Germany) Gmbh Verfahren zur elektrischen Kontaktierung wenigstens eines Kupferlackdrahtes mit einem Bauteil eines Elektromotors, Generators, Sensors oder Elektromagneten mittels an den Kupferlackdrahtenden ausgebildeten elektrischen Kontakten und zusätzlichem Verguss
DE102021111588A1 (de) 2021-05-05 2022-11-10 Bayerische Motoren Werke Aktiengesellschaft Rotor sowie Verfahren zum Herstellen eines Rotors

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2458930A1 (fr) * 1979-06-13 1981-01-02 Paris & Du Rhone Procede de liaison des lames d'un collecteur a des conducteurs et machines electriques tournantes comportant de telles liaisons
US5019739A (en) * 1986-10-17 1991-05-28 Mitsubishi Denki Kabushiki Kaisha Dc motor for automotive engine starter

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2458930A1 (fr) * 1979-06-13 1981-01-02 Paris & Du Rhone Procede de liaison des lames d'un collecteur a des conducteurs et machines electriques tournantes comportant de telles liaisons
US5019739A (en) * 1986-10-17 1991-05-28 Mitsubishi Denki Kabushiki Kaisha Dc motor for automotive engine starter

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3083026A1 (fr) * 2018-06-25 2019-12-27 Valeo Equipements Electriques Moteur Procede de connexion de fils sur un collecteur de moteur electrique

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Publication number Publication date
DE102011088697A1 (de) 2013-06-20

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