JP2009105997A - Manufacturing method of commutator, and manufacturing apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a commutator and a manufacturing apparatus, capable of improving the manufacturing efficiency. <P>SOLUTION: This manufacturing method of a commutator is provided with a first step of relatively moving a cutting tool 16 with respect to a commutator base material 56, from one side (Z1 side) of the axial direction of a commutator base material 56 to the other side (Z2 side), while relatively moving the cutting tool 16 in the circumferential direction of the commutator base material 56, and cutting the external circumferential surface of the commutator base material 56 by using the cutting tool 16; and a second step of relatively moving the cutting tool 16, with respect to the commutator base material 56 from the other side (Z2 side) of the axial direction of the commutator base material 56 to the one side (Z1 side), while relatively moving the cutting tool 16 in the circumferential direction of the commutator base material 56, and cutting the external circumferential surface of the commutator base material 56 by using the cutting tool 16. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a commutator manufacturing method and a manufacturing apparatus, and more particularly, to a commutator manufacturing method and a manufacturing apparatus for manufacturing a commutator from the commutator material by cutting the outer peripheral surface of the commutator material with a cutting tool.

Conventionally, as a commutator manufacturing method and manufacturing apparatus, for example, there is the following (for example, see Patent Document 1). In the example described in Patent Document 1, after the outer peripheral surface of the commutator material is roughly cut, finish cutting is performed to remove burrs generated by the rough cutting, and the commutator is manufactured from the commutator material. ing.
JP 7-163092 A JP 2004-289921 A

  However, when the commutator material is cut to produce a commutator from the commutator material, the commutator material is only moved when the cutting tool is moved relative to the commutator material from one side to the other in the axial direction (during forward movement). When cutting the outer peripheral surface of the metal and cutting the tool relative to the commutator material from the other side in the axial direction from one side to the other (when moving in the return path), the cutting tool is rectified. It is useless to move relative to the child material from the other side in the axial direction to one side, and the production efficiency is lowered.

  This invention is made | formed in view of the said subject, Comprising: It aims at providing the manufacturing method and manufacturing apparatus of a commutator which can improve production efficiency.

  In order to solve the above-mentioned problem, the commutator manufacturing method according to claim 1, wherein the commutator material is moved relative to the commutator material in the circumferential direction of the commutator material, and one side of the commutator material in the axial direction. A first step of cutting the outer peripheral surface of the commutator material with the cutting tool by relative movement from the commutator material to the other side, and moving the cutting tool relative to the commutator material in the circumferential direction of the commutator material. And a second step of cutting the outer peripheral surface of the commutator material with the cutting tool by relatively moving the commutator material from the other side in the axial direction to the one side.

  According to the method for manufacturing a commutator according to claim 1, when the commutator material is cut to manufacture the commutator from the commutator material, the cutting tool is moved from one side to the other side in the axial direction with respect to the commutator material. In addition to the relative movement (during forward movement), the cutting tool can also be used to move the outer peripheral surface of the commutator material relative to the commutator material from the other side in the axial direction to one side (during backward movement). Cut by. Accordingly, it is possible to prevent wasteful movement of the cutting tool relative to the commutator material from the other side in the axial direction to the other side, thereby improving production efficiency.

  The commutator manufacturing method according to claim 2 is the commutator manufacturing method according to claim 1, wherein the cutting tool is moved to the first after the end of the first step and before the start of the second step. It is characterized in that the commutator material is relatively moved inward in the radial direction of the commutator material after being reversely moved from the end position in the process to one side in the axial direction of the commutator material.

  Temporarily, after the end of the first step and before the start of the second step, the cutting tool is moved relative to the commutator material from the end position in the first step to the inside of the commutator material in the radial direction, toward the second step. When the cutting operation is performed, the cutting volume with respect to the commutator material of the cutting tool increases during the cutting operation toward the second step, and as a result, the cutting resistance acting on the cutting tool is reduced. There is a possibility that the wear acceleration of the cutting tool and the quality of the finish of the commutator (for example, the quality related to roundness, the level difference between the segments, the surface roughness of the outer peripheral surface, the complete removal of burrs, etc.) may decrease.

  In this regard, according to the method for manufacturing a commutator according to claim 2, the cutting tool is moved from the end position in the first step to the axial direction of the commutator material after the end of the first step and before the start of the second step. After the reversal movement to the side, the commutator material is moved relative to the inside of the commutator material in the radial direction (so-called two-stage movement) to perform a cutting operation toward the second step. Therefore, the cutting volume with respect to the commutator material of the cutting tool can be reduced during the cutting operation toward the second step, and the cutting resistance acting on the cutting tool can be reduced. This suppresses the deterioration of cutting tool wear acceleration and commutator finish quality (for example, roundness, level difference between segments, surface roughness of the outer peripheral surface, and complete removal of burrs). be able to.

  The commutator manufacturing method according to claim 3 is the commutator manufacturing method according to claim 1, wherein the cutting tool is moved to the first after the end of the first step and before the start of the second step. It is characterized by moving relative to the commutator material radially inward of the commutator material while being reversely moved from the end position in the process to one side in the axial direction of the commutator material.

  According to the method for manufacturing a commutator according to claim 3, the cutting tool is reversed from the end position in the first step to the one side in the axial direction of the commutator material after the end of the first step and before the start of the second step. While moving, the commutator material is moved relative to the inside of the commutator material in the radial direction to perform a cutting operation toward the second step. Therefore, the cutting volume with respect to the commutator material of the cutting tool can be reduced during the cutting operation toward the second step, and the cutting resistance acting on the cutting tool can be reduced. This suppresses the deterioration of cutting tool wear acceleration and commutator finish quality (for example, roundness, level difference between segments, surface roughness of the outer peripheral surface, and complete removal of burrs). be able to.

  Further, in addition to this, the cutting tool is moved relative to the commutator material radially inward with respect to the commutator material while being reversed and moved from the end position in the first step to the one side in the axial direction of the commutator material. Compared with the case where the so-called two-stage movement is performed, the moving path of the cutting tool can be shortened. Thereby, since the time between a 1st process and a 2nd process becomes short, production efficiency can be improved further.

  The method for manufacturing a commutator according to claim 4 is the method for manufacturing a commutator according to any one of claims 1 to 3, wherein the outer peripheral surface of the commutator material is the first step in the first step. Rough cutting is performed with a cutting tool, and the outer peripheral surface of the commutator material is finish-cut with the cutting tool in the second step.

  According to the method for manufacturing a commutator according to claim 4, after the outer peripheral surface of the commutator material is roughly cut with a cutting tool in the first step, the outer peripheral surface of the commutator material is finish-cut with a cutting tool in the second step. Therefore, it is possible to ensure the quality of the finished commutator (for example, the quality related to roundness, the step between each segment, the surface roughness of the outer peripheral surface, the complete removal of burrs, etc.) while improving the production efficiency.

  The commutator manufacturing method according to claim 5 is the commutator manufacturing method according to claim 4, wherein, in the first step, a rough cutting blade surface formed on a cutting bit of the cutting tool is used. Rough cutting the outer peripheral surface of the commutator material, and in the second step, the outer peripheral surface of the commutator material is finish-cut using a cutting surface for finishing cutting formed on the cutting tool. And

  According to the method for manufacturing a commutator according to claim 5, a rough cutting blade surface for rough cutting the outer peripheral surface of the commutator material, and a finish cutting blade for finishing cutting the outer peripheral surface of the commutator material. And a cutting tool having a surface. Therefore, it is not necessary to use dedicated cutting tools for rough cutting (first process) and finishing cutting (second process). For this reason, separate cutting tools are used for rough cutting and finishing cutting, each cutting tool is exchanged between rough cutting and finishing cutting, and the cutting tool is optimized for rough cutting and finishing cutting. There is no need to tilt it at an angle. Thereby, production efficiency can be further improved.

  The commutator manufacturing method according to claim 6 is the commutator manufacturing method according to claim 4, wherein an angle θ1 formed by the rough cutting blade surface and the axial surface of the commutator material and the finish. The cutting tool in which the relationship between the angle θ2 formed by the cutting blade surface and the axial surface of the commutator material satisfies θ1 ≧ θ2 is used.

  According to the method for manufacturing a commutator according to claim 6, the angle θ <b> 1 formed between the rough cutting blade surface and the axial surface of the commutator material, and the finish cutting blade surface and the axial surface of the commutator material. A cutting tool satisfying θ1 ≧ θ2 in relation to the formed angle θ2 is used. Thereby, it is possible to perform rough cutting and finish cutting of the outer peripheral surface of the commutator material with one cutting tool.

  In order to solve the above-described problem, the commutator manufacturing apparatus according to claim 7 includes a cutting tool and a peripheral for moving the cutting tool relative to the commutator material in a circumferential direction of the commutator material. Direction drive means, axial drive means for moving the cutting tool relative to the commutator material in the axial direction of the commutator material, and control of driving of the circumferential drive means and the axial drive means. Control means, wherein the control means controls the driving of the circumferential drive means so that the cutting tool is moved relative to the commutator material in the circumferential direction of the commutator material. A first step of controlling the driving of the axial driving means so that the tool is relatively moved from one axial side to the other side of the commutator material and cutting the outer peripheral surface of the commutator material by the cutting tool. And the cutting worker The cutting tool is moved from the other side in the axial direction of the commutator material to the one side while controlling the driving of the circumferential drive means so that the commutator material is relatively moved in the circumferential direction of the commutator material. And controlling the driving of the axial driving means so as to be relatively moved, and performing a second step of cutting the outer peripheral surface of the commutator material by the cutting tool.

  According to the commutator manufacturing apparatus according to claim 7, when the commutator material is cut and the commutator is manufactured from the commutator material, the cutting tool is moved from one side in the axial direction to the other side of the commutator material. When the cutting tool is moved relative to the commutator material from the other side in the axial direction to the other side (during backward travel), in addition to the relative movement of the commutator material Is cut by a cutting tool. Therefore, it is possible to prevent wasteful movement of the cutting tool relative to the commutator material from the other side in the axial direction to the one side, thereby improving production efficiency.

  The commutator manufacturing apparatus according to claim 8 is the commutator manufacturing apparatus according to claim 7, wherein the cutting tool is moved relative to the commutator material in a radial direction of the commutator material. Direction drive means, and the control means controls the drive of the axial direction drive means after the execution of the first step and before the execution of the second step, so that the cutting tool is moved in the first step. After the reverse movement from the end position to one side of the commutator material in the axial direction, the driving of the radial driving means is controlled to move the cutting tool relative to the commutator material inward in the radial direction of the commutator material. It is characterized by that.

  Temporarily, after the execution of the first step in the control means and before the start of the execution of the second step, the drive of the radial driving means is controlled so that the cutting tool is commutated from the end position in the first step to the commutator material. When the cutting operation toward the second step is performed relative to the radial inner side of the cutting tool, the cutting tool cuts the commutator material during the cutting operation toward the second step. As a result, the cutting force acting on the cutting tool increases, resulting in increased wear resistance of the cutting tool and the quality of the finish of the commutator (for example, roundness, step between segments, surface roughness of the outer peripheral surface) , Quality related to complete removal of burrs, etc.) may be deteriorated.

  In this regard, according to the commutator manufacturing apparatus according to claim 8, the driving of the axial driving means is controlled after the execution of the first step in the control means and before the execution of the second step, whereby the cutting tool is controlled. Is moved from the end position in the first step to one side in the axial direction of the commutator material, and then the driving of the radial drive means is controlled to move the cutting tool relative to the commutator material inward in the radial direction of the commutator material. (So-called two-stage movement). Therefore, during the cutting operation toward the second step, the cutting volume of the cutting tool with respect to the commutator material can be reduced, and the cutting resistance acting on the cutting tool can be reduced. This suppresses the deterioration of cutting tool wear acceleration and commutator finish quality (for example, roundness, level difference between segments, surface roughness of the outer peripheral surface, and complete removal of burrs). be able to.

  The commutator manufacturing apparatus according to claim 9 is a commutator manufacturing apparatus according to claim 7, wherein the cutting tool is moved relative to the commutator material in a radial direction of the commutator material. Direction driving means, and the control means controls the driving of the axial direction driving means and the radial direction driving means after the completion of the execution of the first step and before the execution of the second step. Is moved relative to the commutator material inward in the radial direction of the commutator material while being reversely moved from the end position in the first step to one side in the axial direction of the commutator material.

  According to the commutator manufacturing apparatus of the ninth aspect, the driving of the axial driving means and the radial driving means is controlled after the execution of the first step in the control means and before the execution of the second step. The cutting tool is moved relative to the commutator material inward in the radial direction of the commutator material while being reversely moved from the end position in the first step to one side in the axial direction of the commutator material. Therefore, during the cutting operation toward the second step, the cutting volume of the cutting tool with respect to the commutator material can be reduced, and the cutting resistance acting on the cutting tool can be reduced. This suppresses the deterioration of cutting tool wear acceleration and commutator finish quality (for example, roundness, level difference between segments, surface roughness of the outer peripheral surface, and complete removal of burrs). be able to.

  In addition to this, the cutting tool is moved relative to the commutator material radially inward from the commutator material while being reversely moved from the end position in the first step to the one side in the axial direction of the commutator material. The moving path of the cutting tool can be shortened as compared with the above-described so-called two-stage movement. Thereby, since the time between the first step and the second step is shortened, the production efficiency can be further improved.

  The commutator manufacturing apparatus according to claim 10 is the commutator manufacturing apparatus according to any one of claims 7 to 9, wherein the control means is the commutator material in the first step. The outer peripheral surface of the commutator is rough-cut with the cutting tool, and the outer peripheral surface of the commutator material is finish-cut with the cutting tool in the second step.

  According to the commutator manufacturing apparatus according to claim 10, the outer peripheral surface of the commutator material is roughly cut by the cutting tool, and then the outer peripheral surface of the commutator material is finish-cut by the cutting tool. The quality of the commutator finish (for example, quality related to roundness, level difference between segments, surface roughness of the outer peripheral surface, complete removal of burrs, etc.) can be ensured while improving.

  The commutator manufacturing apparatus according to claim 11 is the commutator manufacturing apparatus according to claim 10, wherein the cutting tool includes a rough cutting blade surface for rough cutting the outer peripheral surface of the commutator material. And a cutting tool having a finishing cutting edge surface for finishing cutting the outer peripheral surface of the commutator material.

  According to the commutator manufacturing apparatus of claim 11, the cutting tool includes a rough cutting blade surface for rough cutting the outer peripheral surface of the commutator material, and a finish cutting of the outer peripheral surface of the commutator material. And a cutting surface for finishing cutting. Therefore, it is not necessary to use dedicated cutting tools for rough cutting (first process) and finishing cutting (second process). For this reason, separate cutting tools are used for rough cutting and finishing cutting, each cutting tool is exchanged between rough cutting and finishing cutting, and the cutting tool is optimized for rough cutting and finishing cutting. There is no need to tilt it at an angle. Thereby, production efficiency can be further improved.

  The commutator manufacturing apparatus according to claim 12 is the commutator manufacturing apparatus according to claim 11, wherein the cutting bit is an angle formed by the rough cutting blade surface and the axial surface of the commutator material. The relationship between θ1 and the angle θ2 formed by the finish cutting blade surface and the axial surface of the commutator material satisfies θ1 ≧ θ2.

  According to the commutator manufacturing apparatus according to claim 12, the cutting tool includes an angle θ <b> 1 formed by the rough cutting blade surface and the axial surface of the commutator material, and the shaft of the finish cutting blade surface and the commutator material. The relationship between the angle θ2 and the directional surface satisfies θ1 ≧ θ2. Thereby, it is possible to perform rough cutting and finish cutting of the outer peripheral surface of the commutator material with one cutting tool.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  1 and 2 show the overall configuration of a commutator manufacturing apparatus 10 according to an embodiment of the present invention. A commutator manufacturing apparatus 10 shown in these drawings is for manufacturing a commutator of an armature 50 provided in a DC motor with a brush, for example, a support base 12, a rotating mechanism 14, a cutting tool 16, and the like. The input operation unit 18, the circumferential drive motor 20, the axial drive motor 22, the radial drive motor 24, and the control circuit 26 are configured.

  The support base 12 includes a pair of support portions 28, and the support portions 28 are configured to rotatably support both axial end portions of the rotary shaft 52 provided in the armature 50. .

  The rotating mechanism 14 includes a driving belt 30, a driving pulley 32, and a plurality of driven pulleys 34A to 34D. The drive belt 30 is looped over a drive pulley 32 and a plurality of driven pulleys 34A to 34D. Of the plurality of driven pulleys 34A to 34D, the pair of driven pulleys 34A and 34B arranged on the armature 50 side is relative to the outer peripheral portion 54A of the core 54 provided in the armature 50 (in this case, the upper end in the vertical direction). It is arranged offset to the rotating shaft 52 side, and a portion of the drive belt 30 between the pair of driven pulleys 34A, 34B is pressed against the core 54. In the rotating mechanism 14, when the driving pulley 32 is rotated, the driving belt 30 is rotated to rotate the entire armature 50 together with the core 54.

  The cutting tool 16 is disposed to face the commutator material 56 (a member at a stage before becoming the commutator 58) in the radial direction. FIG. 3 shows the cutting tool 16 in more detail. The cutting tool 16 includes a holder 36 and a cutting tool 38 as shown in FIGS. 3 (A) and 3 (B). The cutting tool 38 is exchangeably held at the tip of the holder 36 and, as shown in FIG. 3C, rough cutting for rough cutting of the rake face 38A and the outer peripheral surface of the commutator material 56. The blade surface 38B (first flank) for cutting and the blade surface 38C (second flank) for finishing cutting the outer peripheral surface of the commutator material 56 are configured.

  The angle (first clearance angle) θ1 formed between the rough cutting blade surface 38B and the axial surface 56A of the commutator material 56, and the angle formed between the finishing cutting blade surface 38C and the axial surface 56A of the commutator material 56. The relationship with (second clearance angle) θ2 is set to θ1 ≧ θ2, for example, angle θ1 is set to 68 °, and angle θ2 is set to 35 °. The cutting edge tip 38D of the cutting tool 38 is made of diamond or the like and has a nose radius shape to prevent damage when cutting into the commutator material 56.

  The input operation unit 18 can input machining conditions such as a feed speed, a feed amount, and a cutting amount, and commands for start and end of machining, and the circumferential drive motor 20 uses the drive pulley 32 described above. It is configured to rotate.

  The axial drive motor 22 is configured to move the cutting tool 16 in the axial direction of the commutator material 56 with respect to the commutator material 56, and the radial drive motor 24 is configured as described above. 16 is configured to move in the radial direction of the commutator material 56 with respect to the commutator material 56.

  The control circuit 26 is constituted by an electronic circuit having, for example, a CPU, a ROM, a RAM, and the like, and a program for rough cutting and finishing cutting of the commutator material 56 (that is, the first step and the second step in the present invention). Program) in advance.

  Then, the control circuit 26, based on the machining conditions such as the feed speed, feed amount, and cutting amount input from the input operation unit 18 and the machining start and machining end commands, the circumferential drive motor 20 and the axial direction described above. The driving motor 22 and the radial driving motor 24 are controlled to perform rough cutting and finish cutting of the commutator material 56 with the cutting tool 16.

  Next, a commutator manufacturing method using the commutator manufacturing apparatus 10 having the above-described configuration will be described.

  When a machining start command is input to the input operation unit 18, the control circuit 26 controls the driving of the axial direction driving motor 22 and the radial direction driving motor 24, and the cutting tool 16 is moved by the arrow (1) in FIG. As shown, the commutator material 56 is moved from the origin position to one side (Z1 side) in the axial direction. At this time, the position of the tip of the cutting bit 38 is set in accordance with the cutting amount of the next rough cutting.

  Subsequently, the control circuit 26 controls driving of the circumferential driving motor 20 to rotate the driving pulley 32. As a result, the drive belt 30 is rotated, and the commutator material 56 is rotated together with the armature 50.

(First step: rough cutting)
Subsequently, the control circuit 26 controls the driving of the axial drive motor 22 while rotating the commutator material 56, and the cutting tool 16 is moved to the commutator material 56 as indicated by the arrow (2) in FIG. 2. Move from one axial side (Z1 side) to the other side (riser side; Z2 side). At this time, the cutting tool 16 is moved so that the rough cutting blade surface 38B of the cutting tool 38 shown in FIG. 3C faces the traveling direction (that is, the other side in the axial direction; Z2 side). Thereby, the outer peripheral surface of the commutator material 56 is rough cut from one side in the axial direction to the other side.

(After the end of the first step and before the start of the second step)
Subsequently, the control circuit 26 controls the driving of the axial direction drive motor 22, and the rough cutting blade surface 38 B of the cutting tool 38 is against the uncut surface 56 B of the commutator material 56 as shown in FIG. As shown by the arrow (A) in FIG. 4, the commutator material 56 is moved from the end position in the first step (position indicated by a two-dot chain line) so that the cutting tool 16 is separated from one side in the axial direction (Z1 side). Is reversed and moved to one side (Z1 side) in the axial direction.

  Thereafter, the control circuit 26 controls the driving of the radial direction driving motor 24, and the cutting tool 16 is moved from the above-mentioned position by the cutting amount of the next finishing cutting as shown by the arrow (B) in FIG. Move radially inward (R1 side).

(Second process: finish cutting)
Subsequently, the control circuit 26 controls the driving of the axial driving motor 22 while rotating the commutator material 56, and the cutting tool 16 is moved to the commutator material 56 as indicated by an arrow (3) in FIG. 2. Move from the other side in the axial direction (riser side; Z2 side) to one side (Z1 side). At this time, the cutting tool 16 is moved so that the finish cutting blade surface 38C of the cutting tool 38 shown in FIG. 3C faces the traveling direction (that is, one side in the axial direction; Z1 side). Thereby, the outer peripheral surface of the commutator material 56 is finish-cut from the other side in the axial direction to one side.

  Subsequently, the control circuit 26 controls the driving of the axial direction driving motor 22 and the radial direction driving motor 24 so that the cutting tool 16 is moved in the axial direction of the commutator material 56 as indicated by an arrow (4) in FIG. Return to the home position from one side (Z1 side).

(Deburring process)
Then, the commutator material 56 is conveyed to the deburring step as shown in FIG. In this deburring step, the commutator material 56 is removed of the burrs and the like left in the undercut groove by the nylon brush 40 of the deburring device. In the commutator manufacturing method according to the embodiment of the present invention, the commutator 58 is manufactured from the commutator material 56 in the above manner.

  In the present embodiment, the operation performed by the control circuit 26 in the first step described above corresponds to the first step in the present invention, and the operation performed by the control circuit 26 in the second step described above is the second step in the present invention. It corresponds to a step.

  Next, the effect of the commutator manufacturing method according to the embodiment of the present invention described above will be described.

  Here, in order to clarify the effect of the commutator manufacturing method according to the embodiment of the present invention, a commutator manufacturing method according to a comparative example will be described.

  8 and 9 show the overall configuration of a commutator manufacturing apparatus 110 used in the commutator manufacturing method according to the comparative example. The commutator manufacturing apparatus 110 according to this comparative example has the same mechanical configuration as the commutator manufacturing apparatus 10 according to the above-described embodiment of the present invention except for the cutting tool 116.

  In the commutator manufacturing apparatus 110 according to the comparative example, the input operation unit 18, the circumferential drive motor 20, the axial drive motor 22, the radial drive motor 24, and the control circuit 26 are illustrated. These are omitted, and reference is made to FIG. 1 for these. In the commutator manufacturing apparatus 110 according to the comparative example, the same reference numerals are used for the same configuration as the commutator manufacturing apparatus 10 according to the embodiment of the present invention.

  In the commutator manufacturing method according to the comparative example, separate commutator manufacturing apparatuses 110 are used for rough cutting and finish cutting, respectively. That is, the commutator manufacturing apparatus 10 shown in FIG. 8 is for rough cutting, and the commutator manufacturing apparatus 110 shown in FIG. 9 is for finishing cutting.

  FIG. 10 shows a cutting tool 116 provided in the commutator manufacturing apparatus 110 according to the comparative example. As shown in FIG. 10, the cutting tool 116 includes a holder 136 and a cutting tool 138. The cutting tool 138 is exchangeably held at the tip of the holder 136, and as shown in FIG. 10C, a rake face 138A, a first flank 138B, a second flank 138C, , And so on. The cutting edge tip 138D of the cutting bit 138 has a sharp edge shape.

  In the commutator manufacturing apparatus 110 according to this comparative example, commutators are manufactured by the following method.

  That is, in the commutator manufacturing apparatus 110 for rough cutting shown in FIG. 8, when a machining start command is input to the input operation unit 18, the control circuit 26 and the axial driving motor 22 and the radial driving motor The driving of the motor 24 is controlled, and the cutting tool 116 is moved from the origin position to one side (Z1 side) in the axial direction of the commutator material 56 as indicated by an arrow (1) in FIG. At this time, the position of the tip of the cutting tool 138 is set in accordance with the cutting amount of the next rough cutting process.

  Subsequently, the control circuit 26 controls driving of the circumferential driving motor 20 to rotate the driving pulley 32. As a result, the drive belt 30 is rotated, and the commutator material 56 is rotated together with the armature 50.

(First step: rough cutting)
Subsequently, the control circuit 26 controls the driving of the axial direction driving motor 22 while rotating the commutator material 56, and the cutting tool 116 is moved to the commutator material 56 as indicated by an arrow (2) in FIG. 8. Move from one axial side (Z1 side) to the other side (riser side; Z2 side). At this time, the cutting tool 116 is moved so that the first flank 138B of the cutting tool 138 shown in FIG. 10C faces the traveling direction (that is, the other side in the axial direction; Z2 side). Thereby, the outer peripheral surface of the commutator material 56 is rough cut from one side in the axial direction to the other side.

(After the end of the first step and before the start of the second step)
Subsequently, the control circuit 26 controls the driving of the radial drive motor 24 and moves the cutting tool 116 radially outward of the commutator material 56 from the end position in the first step as indicated by the arrow (3) in FIG. Evacuate to. Thereafter, the control circuit 26 controls the driving of the axial direction driving motor 22 and the radial direction driving motor 24, and the cutting tool 116 is moved from the retraction position to the origin as indicated by the arrow (4) in FIG. Return to position.

  Then, the commutator 58 is conveyed to the commutator manufacturing apparatus 110 for finish cutting as shown in FIG. 9 after the above rough cutting. When the commutator manufacturing apparatus 110 that is common to rough cutting and finishing cutting is used, the cutting tool 138 is exchanged from rough cutting to finishing cutting, or to the next finishing cutting. Therefore, it is necessary to incline the cutting tool 116 at an optimum angle.

(Second process: finish cutting)
Then, in the finishing cutting commutator manufacturing apparatus 110 shown in FIG. 9, when the machining start command is input to the input operation unit 18, the control circuit 26 and the axial driving motor 22 and the radial driving motor The drive of the motor 24 is controlled, and the cutting tool 116 is again moved from the origin position to one side (Z1 side) in the axial direction of the commutator material 56 as indicated by an arrow (5) in FIG. At this time, the position of the tip of the cutting tool 138 is set in accordance with the cutting amount of the next finish cutting process.

  Subsequently, the control circuit 26 controls driving of the circumferential driving motor 20 to rotate the driving pulley 32. As a result, the drive belt 30 is rotated, and the commutator material 56 is rotated together with the armature 50.

(Second process: finish cutting)
Subsequently, the control circuit 26 controls the driving of the axial drive motor 22 while rotating the commutator material 56, and the cutting tool 116 is moved to the commutator material 56 as indicated by an arrow (6) in FIG. 9. Move from one axial side (Z1 side) to the other side (riser side; Z2 side). At this time, the cutting tool 116 is moved so that the first flank 138B of the cutting tool 138 shown in FIG. 10C faces the traveling direction (that is, the other side in the axial direction; Z2 side). Thereby, the outer peripheral surface of the commutator material 56 is finish-cut from the one side in the axial direction to the other side.

  Subsequently, the control circuit 26 controls the driving of the radial driving motor 24 and moves the cutting tool 116 radially outward of the commutator material 56 from the end position in the first step as shown by the arrow (7) in FIG. Evacuate to. Thereafter, the control circuit 26 controls the driving of the axial direction driving motor 22 and the radial direction driving motor 24, and the cutting tool 116 is moved from the retraction position to the origin as shown by the arrow (8) in FIG. Return to position.

(Deburring process)
Subsequently, the commutator material 56 is transported to the deburring step as shown in FIG. 7 after the above-described cutting process. In this deburring step, the commutator material 56 is removed of the burrs and the like left in the undercut groove by the nylon brush 40 of the deburring device. In the commutator manufacturing method according to the comparative example, the commutator 58 is manufactured from the commutator material 56 in the manner described above.

  However, when the commutator material 56 is cut and the commutator 58 is manufactured from the commutator material 56 as in the commutator manufacturing method according to the comparative example described above, the cutting tool 116 is pivoted with respect to the commutator material 56. The outer peripheral surface of the commutator material 56 is cut only when the relative movement from one direction (Z1 side) to the other side (Z2 side) is performed (during forward movement), and the cutting tool 116 is axially opposite to the commutator material 56. When the air cut for returning to the home position is performed when the relative movement from the (Z2 side) to the one side (Z1 side) (return movement) is performed, the cutting tool 116 is moved to the commutator material 56 in the other axial direction ( The relative movement from the Z2 side to the one side (Z1 side) is useless, and the production efficiency is reduced.

  In contrast, according to the method for manufacturing a commutator according to an embodiment of the present invention, as shown in FIG. 2, when the commutator material 56 is cut to manufacture the commutator 58 from the commutator material 56. In addition to when the cutting tool 16 is moved relative to the commutator material 56 in the axial direction from one side (Z1 side) to the other side (Z2 side) (during forward movement), the cutting tool 16 is moved relative to the commutator material 56. The outer peripheral surface of the commutator material 56 is also cut by the cutting tool 16 when the relative movement is made from the other side (Z2 side) in the axial direction to the one side (Z1 side) (when moving in the return path). Therefore, it is possible to prevent wasteful movement of the cutting tool 16 relative to the commutator material 56 from the other axial side (Z2 side) to the one side (Z1 side), thereby improving production efficiency. be able to.

  Moreover, according to the method for manufacturing a commutator according to an embodiment of the present invention, after the outer peripheral surface of the commutator material 56 is roughly cut by the cutting tool 16 in the first step, the outer periphery of the commutator material 56 in the second step. Since the surface is finish-cut with the cutting tool 16, the quality of the finish of the commutator 58 (for example, roundness, steps between segments, surface roughness of the outer peripheral surface, complete removal of burrs, etc., while improving production efficiency) Quality).

  Here, for example, after the first step is finished and before the second step is started, for example, as indicated by an arrow (A) in FIG. If the cutting operation toward the second step is performed by moving the commutator material 56 relative to the commutator material 56 in the radial direction (R1 side) from the position of the commutator material 56, the second step When the cutting operation is directed toward, the cutting volume of the cutting tool 16 with respect to the commutator material 56 (that is, the portion indicated by the oblique line Q3) increases, and as a result, the cutting resistance acting on the cutting tool 16 increases and cutting is performed. There is a possibility that the wear quality of the cutting tool 38 and the quality of the finish of the commutator 58 (for example, quality related to roundness, level difference between the segments, surface roughness of the outer peripheral surface, complete removal of burrs, etc.) may be deteriorated.

  In this regard, according to the method of manufacturing a commutator according to an embodiment of the present invention, as shown by arrows (A) and (B) in FIG. 4 after the end of the first step and before the start of the second step. Then, the cutting tool 16 is reversely moved from the end position in the first step (the position indicated by the two-dot chain line) to one side (Z1 side) in the axial direction of the commutator material 56, and then the commutator material 56 with respect to the commutator material 56. Is moved relative to the inner side in the radial direction (R1 side) (so-called two-stage movement) to perform a cutting operation toward the second step. Therefore, during the cutting operation toward the second step, the cutting volume of the cutting tool 16 with respect to the commutator material 56 (that is, the portion indicated by the oblique line Q1) can be reduced, and the cutting resistance acting on the cutting tool 16 is reduced. Can be made. As a result, the wear acceleration of the cutting tool 38 and the quality of the finish of the commutator 58 (for example, quality related to roundness, level difference between segments, surface roughness of the outer peripheral surface, complete removal of burrs, etc.) are reduced. Can be suppressed.

  In addition, according to the commutator manufacturing method according to an embodiment of the present invention, the rough cutting blade surface 38B for rough cutting the outer peripheral surface of the commutator material 56 and the outer peripheral surface of the commutator material 56 are finish-cut. A cutting tool 38 having a finish cutting blade surface 38C for the purpose is used. Therefore, it is not necessary to use dedicated cutting tools for rough cutting (first process) and finishing cutting (second process). For this reason, the cutting tool is used separately for rough cutting and finishing cutting, each cutting tool is exchanged between rough cutting and finishing cutting, and the cutting tool 16 is used in accordance with rough cutting and finishing cutting. There is no need to tilt to the optimum angle. Thereby, production efficiency can be further improved.

  Furthermore, according to the commutator manufacturing method according to the embodiment of the present invention, the angle θ1 formed between the rough cutting blade surface 38B and the axial surface 56A of the commutator material 56, the finish cutting blade surface 38C, and the rectification. A cutting tool 38 having a relationship of θ1 ≧ θ2 with respect to the angle θ2 formed with the axial surface 56A of the child material 56 is used. Thereby, it is possible to perform rough cutting and finish cutting of the outer peripheral surface of the commutator material 56 with one cutting tool 38.

  As mentioned above, although one Embodiment of this invention was described, this invention is not limited above, Of course, it can change and implement variously within the range which does not deviate from the main point. .

  For example, in the above embodiment, after the end of the first step and before the start of the second step, as shown in FIG. 4, the cutting tool 16 is moved from the end position in the first step (position indicated by a two-dot chain line). After the commutator material 56 is reversed and moved to one side (Z1 side) in the axial direction, the commutator material 56 is moved relative to the radially inner side (R1 side) of the commutator material 56 (so-called two-stage movement) to be second. Although the cutting operation for the process is performed, the following may be performed.

  That is, after the end of the first step and before the start of the second step, as shown by the arrow (A) in FIG. 5, the cutting tool 16 is rectified from the end position in the first step (the position indicated by the two-dot chain line). The reversing movement to the one side (Z1 side) in the axial direction of the child material 56 is made to move relative to the radially inner side (R1 side) of the commutator material 56 with respect to the commutator material 56 to perform a cutting operation toward the second step. You can go.

  In this way, the cutting volume of the cutting tool 16 relative to the commutator material 56 (that is, the portion indicated by the hatched line Q2) can be reduced during the cutting operation toward the second step, and this acts on the cutting tool 16. Cutting resistance can be reduced. As a result, the wear acceleration of the cutting tool 38 and the quality of the finish of the commutator 58 (for example, quality related to roundness, level difference between segments, surface roughness of the outer peripheral surface, complete removal of burrs, etc.) are reduced. Can be suppressed.

  In addition to this, the cutting tool 16 is reversely moved from the end position in the first step to the one axial side (Z1 side) of the commutator material 56 while the commutator material 56 is radially inward of the commutator material 56. By making the relative movement to the (R1 side), the movement path of the cutting tool 16 can be shortened as compared with the case of performing the so-called two-stage movement described above (in the case of FIG. 5). Thereby, since the time between a 1st process and a 2nd process becomes short, production efficiency can be improved further.

  In the above embodiment, the cutting tool 16 is moved in the circumferential direction of the commutator material 56 with respect to the commutator material 56 by using the rotation mechanism 14 and the circumferential drive motor 20. Means may be used to move at least one of the cutting tool 16 and the commutator material 56 such that the cutting tool 16 is moved relative to the commutator material 56 in the circumferential direction of the commutator material 56. .

  Moreover, in the said embodiment, although the cutting tool 16 was moved to the axial direction of the commutator raw material 56 with respect to the commutator raw material 56 using the axial direction drive motor 22, other axial direction drive means were used. Alternatively, at least one of the cutting tool 16 and the commutator material 56 may be moved so that the cutting tool 16 is moved relative to the commutator material 56 in the axial direction of the commutator material 56.

  Moreover, in the said embodiment, although the cutting tool 16 was moved to the radial direction of the commutator raw material 56 with respect to the commutator raw material 56 using the radial direction drive motor 24, other radial direction drive means were used. Alternatively, at least one of the cutting tool 16 and the commutator material 56 may be moved so that the cutting tool 16 is moved relative to the commutator material 56 in the radial direction of the commutator material 56.

It is a front view which shows the whole structure of the manufacturing apparatus of the commutator which concerns on one Embodiment of this invention. It is a side view which shows the whole structure of the manufacturing apparatus of the commutator which concerns on one Embodiment of this invention. It is a figure which shows the structure of the cutting tool with which the manufacturing apparatus of the commutator which concerns on one Embodiment of this invention was equipped. It is operation | movement explanatory drawing of a cutting tool. It is operation | movement explanatory drawing of a cutting tool. It is operation | movement explanatory drawing of a cutting tool. It is a figure explaining the deburring process for removing the burr | flash of a commutator raw material. It is a figure explaining the manufacturing method of the commutator which concerns on a comparative example. A method for manufacturing a commutator according to a comparative example will be described. It is a figure which shows the structure of the cutting tool with which the manufacturing apparatus of the commutator which concerns on a comparative example was equipped.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Commutator manufacturing apparatus, 14 ... Rotation mechanism (a part of circumferential direction drive means), 16 ... Cutting tool, 20 ... Circumferential direction drive motor (a part of circumferential direction drive means), 22 ... Axial direction drive Motor (axial driving means), 24 ... radial driving motor, 26 ... control circuit (control means), 38 ... cutting tool, 38B ... rough cutting blade surface, 38C ... finish cutting blade surface, 50 ... armature 56 ... Commutator material

Claims (12)

While relatively moving the cutting tool relative to the commutator material in the circumferential direction of the commutator material, the commutator material is relatively moved from one side to the other in the axial direction, and the outer peripheral surface of the commutator material is moved by the cutting tool. The first step of cutting,
While moving the cutting tool relative to the commutator material in the circumferential direction of the commutator material, the cutting tool is moved relative to the commutator material from the other side in the axial direction to the one side to cut the outer peripheral surface of the commutator material. A second step of cutting with a tool;
A method of manufacturing a commutator, comprising: After the end of the first step and before the start of the second step, the cutting tool is reversely moved from the end position in the first step to one side in the axial direction of the commutator material, and then the commutator material is moved. Moving the commutator material radially inward,
The method of manufacturing a commutator according to claim 1. After the end of the first step and before the start of the second step, the cutting tool is reversely moved from the end position in the first step to the one side in the axial direction of the commutator material. Move the commutator material radially inward,
The method of manufacturing a commutator according to claim 1. In the first step, the outer peripheral surface of the commutator material is rough-cut with the cutting tool,
In the second step, the outer peripheral surface of the commutator material is finish-cut with the cutting tool,
The manufacturing method of the commutator as described in any one of Claims 1-3 characterized by the above-mentioned. In the first step, rough cutting of the outer peripheral surface of the commutator material using a rough cutting blade surface formed on a cutting bit of the cutting tool,
In the second step, the outer peripheral surface of the commutator material is finish-cut using a blade surface for finishing cutting formed on the cutting bite,
The method of manufacturing a commutator according to claim 4. The relationship between the angle θ1 formed by the rough cutting blade surface and the axial surface of the commutator material and the angle θ2 formed by the finish cutting blade surface and the axial surface of the commutator material satisfy θ1 ≧ θ2. Use the cutting tool that satisfies you,
The method of manufacturing a commutator according to claim 4. Cutting tools,
Circumferential driving means for moving the cutting tool relative to the commutator material in the circumferential direction of the commutator material;
Axial driving means for moving the cutting tool relative to the commutator material in the axial direction of the commutator material;
Control means for controlling the driving of the circumferential driving means and the axial driving means;
With
The control means includes
While controlling the driving of the circumferential drive means so that the cutting tool is moved relative to the commutator material in the circumferential direction of the commutator material, the cutting tool is moved from one axial direction side of the commutator material. A first step of controlling the driving of the axial driving means so as to be relatively moved to the other side, and cutting the outer peripheral surface of the commutator material by the cutting tool;
While controlling the driving of the circumferential driving means so that the cutting tool is moved relative to the commutator material in the circumferential direction of the commutator material, the cutting tool is moved from the other axial side of the commutator material. A second step of controlling the driving of the axial driving means so as to be relatively moved to one side and cutting the outer peripheral surface of the commutator material by the cutting tool;
Run the
A commutator manufacturing apparatus characterized by that. Radial direction drive means for moving the cutting tool relative to the commutator material in the radial direction of the commutator material,
The control means controls the drive of the axial drive means after the execution of the first step and before the execution of the second step, and moves the cutting tool from the end position in the first step to the commutator. After reversing the material axially to one side, controlling the driving of the radial driving means to move the cutting tool relative to the commutator material radially inward of the commutator material;
The commutator manufacturing apparatus according to claim 7. Radial direction drive means for moving the cutting tool relative to the commutator material in the radial direction of the commutator material,
The control means controls the drive of the axial direction drive means and the radial direction drive means after the completion of the execution of the first step and before the execution of the second step, so that the cutting tool is moved in the first step. Moving relative to the commutator material radially inward relative to the commutator material while reversing and moving from the end position to one side of the commutator material in the axial direction;
The commutator manufacturing apparatus according to claim 7. The control means includes
In the first step, the outer peripheral surface of the commutator material is rough-cut with the cutting tool,
In the second step, the outer peripheral surface of the commutator material is finish-cut with the cutting tool,
The commutator manufacturing apparatus according to any one of claims 7 to 9, wherein the commutator is manufactured. The cutting tool is
A rough cutting blade surface for rough cutting the outer peripheral surface of the commutator material;
A blade surface for finishing cutting to finish-cut the outer peripheral surface of the commutator material;
Configured with a cutting bit having
The commutator manufacturing apparatus according to claim 10. The cutting bit is
The relationship between the angle θ1 formed by the rough cutting blade surface and the axial surface of the commutator material and the angle θ2 formed by the finish cutting blade surface and the axial surface of the commutator material satisfy θ1 ≧ θ2. It is considered to be a satisfactory composition,
The commutator manufacturing apparatus according to claim 11.

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