JPS6217467B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an armature, in which an armature coil used in a rotating electrical machine such as a starting motor is connected to a commutator by ultrasonic welding.

First, a conventional apparatus for carrying out this type of method is shown in FIG. In the figure, 1 is the shaft of the starting motor, 2 is an armature core fitted on this shaft, 3 is an armature coil wound in a slot (not shown) provided in this armature core, and 3a is this armature coil. The outlet portion 4 of the coil is a commutator which does not have a riser portion to which the outlet portion 3a of the amateur coil is electrically and mechanically connected and has approximately the same diameter in the axial direction.
A bush 5 that fits onto the shaft 1, a segment 7 that is arranged in the circumferential direction of the shaft 1 and forms a sliding surface for a brush (not shown), and a molding material 6 that integrally molds the bush 5 and the segment 7.
It consists of Here, in the armature having the above configuration, the outlet portions 3a of the armature coil 3 are connected to each other on the segments 7 by an ultrasonic welding method using an ultrasonic welding device 8, and are spaced apart from each other.
The configuration of the apparatus will be described below. Reference numeral 9 denotes a power supply device for the ultrasonic welding apparatus 8, 10 a coil, 11 a magnetostrictive element, 12 a horn, and 13 a chip.

Next, a method of performing the ultrasonic welding using the ultrasonic welding device 8 described above will be explained. The output of the power source 9 is converted into mechanical vibration by the coil 10 and the magnetostrictive element 11, the amplitude is amplified by the horn 12, and the tip 13 presses the exit part 3a of the armature coil 3 with the pressure P shown in the figure and at the same time moves in the direction F in the figure. Vibration is applied to the outlet part 3 of the amateur coil 3.
a and segment 7 are friction welded by ultrasonic vibration. By the way, the above-mentioned ultrasonic welding behaves more like solid-phase welding than joining by melting the welded parts due to frictional heat, and is essentially a different joining method from conventional arc welding or soldering. It was a difficult method to increase the strength.

Furthermore, since the conventional method of manufacturing an armature by connecting the armature coil 3 by ultrasonic welding is configured as described above, it is necessary to perform end face turning processing by deforming the armature coil 3 after ultrasonic welding. In addition, the commutator surface had to be re-turned due to the segments 7 floating up from the mold 6 due to ultrasonic vibrations. By the way, the above coil 3
And when turning the segment 7, the machining work is interrupted cutting, unlike conventional arc welding, etc.
Since the welding is solid phase welding, the adhesion strength is low and the welded part has the disadvantage of peeling.

This invention was made in order to eliminate the drawbacks of the conventional method as described above, and it is an amateur method that can prevent fatal defects that occur during commutator finishing processing after ultrasonic welding, which causes the joint to peel off. The purpose is to provide a manufacturing method for.

An embodiment of the present invention will be described below with reference to FIGS. 2 and 3. 14 is mainly a thermosetting powder polymer resin insulation molded part (hereinafter referred to as powder coat); 14a is a part of the powder coat 14 that has been subjected to finishing treatment, with the rotary part of the commutator removed;
This turned portion constitutes an installation space for a commutator surface and a brush (not shown) that comes into sliding contact with this surface.

Next, a manufacturing method according to an embodiment of the present invention described above will be explained. In the above configuration, first, the welded part between the outlet part 3a of the armature coil 3 and the segment 7, which were ultrasonically welded by a conventional method, and the vicinity thereof are insulated with a powder polymer resin mold 14, and then, as shown in FIG. As shown in FIG. 2, the end of the outlet portion 3a of the armature coil 3 and the outer periphery of the segment 7, including the molded portion, are turned, and finishing is performed if necessary. With the above configuration, the end processing of the amateur coil 3 in particular is not interrupted cutting, and the reaction force at the end of the coil due to cutting is received by the powder coat 14, which is particularly advantageous in compressive force strength, which tends to occur in conventional machines. The peeling of the welded part will be resolved. Further, by turning the outer circumferential portion of the segment 7, the effect of finishing the commutator surface similar to conventional processing can also be obtained. Furthermore, since the welded part and its vicinity are treated with powder coating 14, it is possible to obtain a product with excellent electric insulation properties, mechanical strength, and heat dissipation properties for amateurs.

In the above embodiment, an armature with a commutator in which the segments 7 are fixed using the mold 6 is shown, but the same applies to an armature with a commutator in which the segments are fixed by a mechanical caulking method. It has a great effect. It is also possible to replace the powder coat 14 with another component of polymer resin. Also powder coat 14
explained that the welded portion is molded, but it is advantageous to reduce manufacturing costs if this is done simultaneously with the electrical insulation treatment of the entire armature. Furthermore, although it has been explained that the commutator surface is also machined at the same time regarding turning after welding, the same effect can be obtained when only the coil end face is machined.

As described above, according to the present invention, after the armature coil 3 and commutator 4 are ultrasonically welded, the periphery is powder coated 14 and the welded part is turned into the required shape. This has the effect of preventing peeling of the welded portion and providing an amateur having a commutator 4 with enhanced electrical insulation, heat resistance, and mechanical strength.

[Brief explanation of the drawing]

FIG. 1 is a block diagram for explaining a method for manufacturing an armature using a conventional ultrasonic welding method, and FIGS. 2 and 3 are cross-sectional views for explaining a method for manufacturing an armature according to an embodiment of the present invention. be. In the figure, 3 is an amateur coil, 3a is an outlet part,
4 is a commutator, 6 is a mold, 7 is a segment, 8 is an ultrasonic welding device, 13 is a chip, 14 is a powder polymer resin insulation part, and 14a is a removed part.
Note that the same reference numerals in each figure indicate the same or corresponding parts.

Claims (1)

[Scope of Claims] 1. An armature coil in which the outlet part of the armature coil is connected to a segment having no riser part of a commutator fixed in the circumferential direction of the shaft by ultrasonic welding at a distance from each other, After the ultrasonic welding, the shaft is insulated by a powder polymer resin mold in the axial and radial directions, including the welded portion between the outlet and the segment, and filling the entire circumference between the ends of the outlet. A method for manufacturing an armature, further comprising cutting the outlet portion of the armature coil including the molded part to create a space for installing a brush that slides into contact with the segment. 2. The method for producing amateurs according to claim 1, wherein the powdered polymer resin is a thermosetting resin.