KR101598772B1 - Commutator, Method for Manufacturing Commutator, and Electric Motor - Google Patents

Abstract

A rectifier (8) for an electric motor of the present invention comprises a substantially cylindrical rectifier main body portion (81) formed of a resin, a conductive main body portion (81) fixed at approximately the same pitch in the circumferential direction of the rectifier main body portion Shaped rectifier piece 82 and a plurality of rectifier pieces 82 which are integrally formed at one end of each of the plurality of plate-shaped rectifier pieces 82. The rectifier piece 82 is bent and extended outwardly toward the other end of the rectifier piece, And includes a lyer 83 wound with a coil wire W of the electric motor. In addition, the distal end of the lyse 83 of the rectifier 8 is provided with a latch means 83a for preventing the coil wire W from being separated during firing.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a commutator,

The present invention relates to a rectifier, a method of manufacturing a rectifier, and an electric motor using the rectifier.

This application is based upon and claims the benefit of priority from U.S. Patent Application No. 2011-185459 filed on August 29, 2011, the contents of which are incorporated herein by reference.

Generally, an electric motor includes a generally cylindrical motor housing, a plurality of magnets arranged on the inner circumferential surface of the motor housing, an armature rotatably supported in the housing, And a brush device for supplying electric power to the armature.

The armature includes a shaft constituting a motor shaft, an armature core fixed to the outside of the shaft, a rectifier fitted and fixed to the outside of the shaft at one end of the armature core, and a coil wound around the armature core and an armature coil composed of a wire.

The rectifier includes a cylindrical commutator main body part formed of a resin and an electroconductive material so as to have substantially the same pitch in the circumferential direction of the outer peripheral surface of the rectifier main body part. and a plurality of plate-shaped commutator pieces fixedly disposed with a pitch. A hook-shaped riser is integrally formed at one end of the rectifier core on the armature core side so as to be turned upside down toward the other end of the rectifier. As described above, the lumen of the rectifier is opposed to the rectifier and is integrally formed. The coil wire is wound around the coil wire extending from the armature core, and the coiled coil wire is clamped and fixed to the rectifier piece together with the lyser.

Here, the coil wire of the rectifier is fixed by winding a coil wire around the coil and then winding the coil wire along with the coil wire. In the fusing process, a pair of electrodes of an anode and a cathode are used, and the electrode rod is brought into contact with the rectifier element, and one electrode rod lowers the coiled wire lyse from the outside in the radial direction. Then, in the fusing process, a current having a high current value flows between the pair of electrode bars while the coils are sandwiched between the lyser and the rectifier by this step-down. By this current, heat is generated between the coil line and the rectifier element and between the coil line and the lyser due to electrical resistance. By this resistance heat, the coil wire is welded to the rectifier piece and the lyser. (See, for example, Patent Document 1).

[Prior Art Literature]

[Patent Literature]

Japanese Patent Application Laid-Open No. 2008-154347

However, in the above conventional art, when the length of the coiled lance is short, when the lysing coil is lowered to the rectifier by the electrode rod, the coiled wire wound around the lysate is pushed by the lyser, .

Therefore, in the prior art, the lyser is set to a predetermined length or longer so that the coil wire is not separated from the lyser. However, when the length of the lyser that is pressed down on the rectifier section is long, the lyser comes in contact with the rectifier section in the axial direction after the fusing. Therefore, the length in the axial direction of the rectifier element is significantly eroded by the lyser, and the length in the axial direction in which the brush can contact the rectifier element is shortened. Therefore, in order to secure a length in the axial direction in which the brush can contact, it is not easy to make the rectifier small in size, because the length in the axial direction of the rectifier element itself is required to be long.

SUMMARY OF THE INVENTION In view of the above, it is an object of the present invention to provide a small rectifier.

According to a first aspect of the present invention, there is provided a rectifier including a substantially cylindrical rectifier main body portion made of resin, a conductive material, and substantially the same pitch A plurality of plate-like rectifier pieces fixedly arranged at one end of each of the plurality of rectifier pieces, and is bent and extended out toward the other end portion of the rectifier device and is opposed to the rectifier piece And a liner wound around a coil wire of the electric motor, wherein the end of the lyser is provided with engaging means for preventing the coil wire from being separated during firing.

According to a first embodiment of the present invention, a latching means for preventing the coil wound on the lyser from separating from the tip of the lyser is provided at the distal end of the lyser. By this engaging means, it is possible to effectively prevent the coil from being pushed away from the distal end of the lyser and separated when the lyser is lowered to the rectifying element by the fusing process. Therefore, it is not necessary to lengthen the lyser to prevent the coil from being separated. As a result, after the fusing process, the axial length in which the lyser is present in the rectifier element can be shortened, and the portion of the rectifier element that is eroded by the lyser in the axial direction length becomes small.

As a result, the length in the axial direction in which the brush contacts the rectifier element can be sufficiently secured without lengthening the length of the rectifier element itself. Therefore, the axial length of the rectifier element and the axial length of the body portion to which the rectifier element is fixed can be shortened. Further, even when the diameter of the coils is large, by providing the engaging means, it is possible to prevent the coils wound on the lizzard from separating from the end of the lizzard without lengthening the lizzard.

According to the second embodiment of the present invention, in the rectifier according to the first embodiment of the present invention, the engaging means of the lyser is a protrusion formed so as to protrude in the radial direction toward the rectifier piece opposed to the lyser.

According to the third embodiment of the present invention, in the rectifier according to the second embodiment of the present invention, the cross section of the lyser is formed in a substantially rectangular shape, and taper processing is applied to both corners of the outer surface .

According to a fourth embodiment of the present invention, a method of manufacturing a rectifier includes a substantially cylindrical rectifier main body portion formed of a resin, a conductive material, and is fixedly arranged at substantially the same pitch in the circumferential direction of the outer peripheral surface of the rectifier main body portion And a plurality of plate-like rectifier pieces integrally formed at one end of each of the plurality of rectifier pieces, which are bent outwardly and protruded toward the other end of the rectifier device and are opposed to the rectifier piece, There is provided a method of manufacturing a rectifier for an electric motor having a liner wound with a line, the method comprising: a ring member forming step of processing a plate material to form a ring member having a plurality of the lyzers extending radially outwardly in a radial direction at one end thereof; A molding process for forming the rectifier main body portion inside the ring member, A step of dividing the member into substantially equal pitches in the circumferential direction to form the rectifier piece; a step of projecting a protruding portion, which is integrally projected in a radial direction toward the rectifier piece opposed to the lyse, in a radially- Forming a step on both of a first surface facing the rectifier element and a second surface opposite to the first surface so as to form a stepped portion and a bending step of bending the lizer toward the rectifier element do.

According to a fifth embodiment of the present invention, in the method of manufacturing a rectifier according to the fourth embodiment of the present invention, both edges of the outer surface of the lyer are tapered in the casting step.

According to a sixth embodiment of the present invention, the electric motor includes a rectifier according to the first embodiment and the second embodiment of the present invention.

According to the rectifier, the length of the rectifier in the axial direction can be shortened, so that a small rectifier can be provided.

1 is a partial sectional view showing an electric motor according to one embodiment of the present invention.
FIG. 2 is a partially enlarged view of the rectifier in FIG. 1; FIG.
3 is a front view showing a rectifier according to one embodiment of the present invention.
Fig. 4 is an enlarged view of a main portion showing the recess of the rectifier indicated by the range A in Fig.
5 is a longitudinal sectional view of the rectifier in Fig.
6A is a schematic view showing a plate member forming a ring member constituting a rectifier element.
6B is a schematic view showing a plate member forming a ring member constituting a rectifier element.
7 is a schematic view for explaining the bending process of the plate member for forming the ring member;
8 is a perspective view of a ring member forming a rectifier element.
Fig. 9 is a perspective view of a ring member bent in a radially outward direction by a lyser.
10 is a schematic diagram illustrating a mold process in a method of manufacturing a rectifier according to an embodiment of the present invention.
11 is an enlarged view of a main part viewed from B and C in the casting process of Fig.
12 is a schematic view for explaining a protrusion forming process in a method of manufacturing a rectifier according to an embodiment of the present invention.
13 is a schematic diagram illustrating a bending process in a method of manufacturing a rectifier according to an embodiment of the present invention.
14 is a schematic diagram illustrating a firing process in a method of manufacturing a rectifier according to one embodiment of the present invention.
15 is a schematic diagram for explaining downsizing of a rectifier according to one embodiment of the present invention.

(Electric motor)

Next, one embodiment of the present invention will be described based on Figs. 1-5. Fig. 1 is a partial cross-sectional view of the electric motor 1 in this embodiment, and Fig. 2 is a partially enlarged view centering on the rectifier 8 in Fig. Fig. 3 is a front view showing the rectifier 8 in the present embodiment, and Fig. 4 is an enlarged view of a main part showing a main part of the rectifier 8 indicated by the range A in Fig. 4 is a longitudinal sectional view of the rectifier 8 in Fig.

1, the electric motor 1 includes a substantially cylindrical motor housing 2, a plurality of magnets 4 disposed on the inner peripheral surface of the motor housing 2, bearings (not shown) disposed in the motor housing 2, And a brush device 3 for supplying electric power to the armature 6 and the armature 6 which are rotatably supported in the motor housing 2 by means of the brushes 5.

The armature 6 includes a shaft 7 constituting a motor shaft, an armature core 9 fitted and fixed to the outside of the shaft 7, an armature core 9 fixed to the outside of the shaft 7 at one end side of the armature core 9 A rectifier 8 and an armature coil 10 constituted by a coil wire W wound on an armature core 9. [

The rectifier 8 includes a substantially cylindrical rectifier main body portion 81 formed of a resin and having a through hole formed in its central portion, a plurality of plate-shaped planar rectilinear main body portions 81 fixedly arranged at substantially the same pitch as the outer peripheral surface of the rectifier main portion 81 A metallic rectifier piece 82 and a lid 83 integrally formed at one end of the rectifier piece 82 on the armature core 9 side.

The lyser 83 formed integrally with the rectifier piece 82 is folded rearward toward the other end of the rectifier piece 82 and integrally formed so as to face the rectifier piece 82, The coil wire W extending from the armature core 9 can be wound and the wound coil wire W is clamped and fixed to the rectifier piece 82 together with the lyser 83 by fusing.

The brush device 3 includes a disc holder 3a in the form of a disc, a brush holder 3b attached to the holder stay 3a and a brush holder 3b which is disposed together with the coil spring 3e in the brush holder 3b, And a brush 3c having a brush 3d. The brush 3c is pressed toward the rectifier 8 by the coil spring 3e. The brush 3c is brought into contact with the rectifier element 82 of the rectifier 8 by a predetermined strong pressure. The detailed structure and manufacturing method of the rectifier 8 will be described later.

In the stator core 9, a plurality of teeth 9a are formed radially outward in the radial direction. The coil wire W is wound on the tooth 9a. The armature coil 10 is formed by the wound coils W in this way. In addition, the coils 10 are electrically connected integrally by a moving line formed on the coil wire W. A part of the coil wire W forming such a moving line can be wound around the lyser 83. [ The coil wire W wrapped around the lyser 83 is mechanically fixed to the rectifier piece 82 by winding a part of the coil wire W around the lyser 83 and then fusing the lyser 83, Respectively. The brush 3c provided on the brush device 3 is brought into contact with the rectifier element 82 so that electric power is supplied to the coil wire W of the armature 6 through the brush 3c and the rectifier element 82 .

(rectifier)

Next, the rectifier 8 in the present embodiment will be described with reference to Figs. 3 to 5. Fig. Particularly, the shape of the lyser 83 will be described. 3 is a front view of the rectifier 8. Fig. 4 is an enlarged view of a main part of the rectifier 8 indicated in the range A in Fig. 5 is a longitudinal sectional view of the rectifier 8. Fig.

The lyser 83 is integrally formed at one end of the rectifier piece 82 and is formed into a substantially rod-like shape having a rectangular cross section. The lyser 83 is integrally formed so as to face the other end of the rectifier element 82 so as to face the rectifier element 82 (facing each other). A protruding portion (engaging means) 83a protruding integrally toward the rectifier element 82 is provided at the front end of the lyer 83. [ The protrusion 83a prevents the coil wire W wound on the lizer 83 from being separated from the lyser 83 during firing when the electric motor 1 is manufactured.

Here, in the present embodiment, the protruding portion 83a protrudes substantially integrally from the tip end of the lyser 83, but is not limited to this form. The projecting portion may be formed as a bent portion integrally projecting with the leading end of the lyser 83 bent toward the rectifier piece 82. Further, the projecting portion may be an engaging means which is mounted toward the rectifier piece 82 from the tip end of the lyser 83. [

Both corners 83c and 83c of the outer surface 83b of the lyer 83 are tapered. By tapering the two corners 83c and 83c of the outer surface 83b of the lyser 83 as described above, when the coil wire W is wound around the lizers 83, the two corners 83c and 83c The coil wire W is prevented from being caught. The coil wire W is easily disposed on the lower portion of the lyser 83 which is the boundary portion between the lyser 83 and the rectifier piece 82. [ As a result, the portion of the lyser 83 which is joined to the rectifier piece 82 at the time of firing is prevented from being eroded by the coil wire W. Therefore, it is not necessary to form the lyser 83 long, and the rectifier 8 can be downsized.

(Manufacturing Method of Rectifier)

Next, a method of manufacturing the rectifier 8 of the present embodiment will be described based on FIG. 6 (a) to FIG. 6 (a) and 6 (b) are schematic views showing a plate member forming a ring member constituting a rectifier piece and a lyse. 7 is a schematic view for explaining the bending process of the plate member for forming the ring member. 6 (a) shows a front view of the plate member. 6 (b) shows a side view of the plate member. 8 is a perspective view of a ring member forming a rectifier element. Fig. 9 is a perspective view of a ring member bent in a radially outward direction; 10 is a schematic diagram for explaining a molding process for forming the rectifier main body portion in the ring member. Fig. 11 is an enlarged view of essential parts viewed from B and C with respect to the casting step in Fig. 10; Fig. 12 is a schematic view for explaining a protrusion forming step for forming a protrusion on the tip of the lyser. 13 is a schematic diagram for explaining a bending process for bending the lyser from the end to a hook shape

(Step of Forming Ring Member)

First, the process of forming the ring member R from a plate material made of a copper material will be described based on Figs. 6 (a) to 9. Here, the ring member R is a member forming the rectifier piece 82 of the rectifier 8 and the lyse 83.

The plate member formed of the band-shaped copper material is formed into the plate member P by punching as shown in Figs. 6 (a) and 6 (b). The plate member P has a plurality of lyers 83 integrally formed on one end side of the strip-shaped rectifier piece P1 and the rectifier piece P1 and arranged at substantially equal intervals. As shown in Fig. 7, the plate member P is bent so that both side ends of the rectifier unit portion P1 come into contact with each other. The plate member P is formed by the ring member R shown in Fig. Then, as shown in Fig. 9, the lyser 83 is bent as if radially extended toward the radially outward side.

(Molding process)

A molding process for forming the rectifier main body portion 81 inside the ring member R will be described with reference to Figs. 10 and 11. Fig. In the casting process, the fixing jig 111 into which the ring member R is inserted and the movable jig 112 which pinches and fixes the ring member R together with the fixing jig 111 are used.

The fixing jig 111 is formed with a circular annular recessed portion. The ring member R is inserted into the indentation. The lyser 83 of the ring member R is disposed in contact with the opening end surface of the fixing jig 111. [ Then, the movable jig 112 moves in the direction indicated by the arrows in Figs. 10 and 11 to hold the lyser 83 therebetween. 11, both edges 112b and 112b of the lower portion of the movable jig 112 are formed in an R shape (curved shape) in the indentation 112a for holding the lyser 83, . Both edges 83c and 83c of the outer surface 83b of the lyser 83 are tapered when the lid 83 is sandwiched by the fixed jig 111 and the movable jig 112. [

The movable jig 112 is provided with a gate G for injecting the resin pl into the indentation of the fixing jig 111. The resin pl is injected from the gate G into the inside of the ring member R. [ Further, the rectifier main body portion 81 is formed by the resin pl thus injected. Thus, the ring member R formed with the rectifier main body portion 81 is separated from the fixing jig 111. [ The cylindrical rectifying part (P1) of the ring member (R) is formed of a plurality of rectifier pieces (82) separated at substantially the same pitch by cutting.

(Projection forming step)

12, in the rectifier 8 before machining according to the protrusion forming process, the lyser 83 extends straightly outwardly in the radial direction from one end of the rectifier piece 82. As shown in Fig. In the protruding portion forming step, a cylindrical first fixing jig 101, a cylindrical second fixing jig 102, and a second fixing jig 102 are rotatably and rotatably connected to the outer periphery of the second fixing jig 102 And a first movable jig 103 which is engaged with the first movable jig 103 is provided. Here, on the end surface of the passage of the first fixing jig 101, a margin portion 101a having a recessed shape is provided on the outer peripheral portion.

The rectifier 8 is inserted into the cylinder of the first fixing jig 101 so that the lyre 83 is held on the opening end surface of the first fixing jig 101. [ The base end portion of the lyser 83 is sandwiched and fixed by the opening end surface and the second fixing jig 102. Then, the first movable jig 103 is operated in the direction of the arrow in FIG. 12 (the direction of the margin portion 101a). By this direct action (press), the leading end portion of the lyre 83 is significantly projected in the direction of the margin portion 101a as compared with the main body portion of the lyre 83. [ The protruding portion (engaging means) 83a is formed at the tip of the lyser 83 by the remarkable protrusion of the tip portion

(Bending process)

As shown in Fig. 13, a projecting portion (engaging means) 83a is formed at the tip end of the lyser 83 of the rectifier 8 before machining according to the bending process. On the other hand, the lyser 83 extends straightly outward in the radial direction at a right angle from one end of the rectifier element 82. Here, in the bending process, the third fixing jig 104 and the third fixing jig 104, which have a cylindrical shape and have a bottom portion, and a cylindrical portion having a bottom portion into which the rectifier 8 is inserted A fifth fixing jig 106 in the form of a cylinder for holding and fixing both end surfaces of the rectifier 8 together with the fourth fixing jig 105 and the fourth fixing jig 105, (Not shown).

The opening end of the fourth fixing jig 105 is formed in a thin ring shape. The base end of the lyer 83 is supported by such a ring-shaped thin portion. The opening of the inner circumferential surface of the second movable jig 107 is formed in a tapered shape whose diameter gradually decreases from the opening surface. In addition, in the second movable jig 107, the outer peripheral surface is guided to the inner peripheral surface of the third fixed jig 104, and the inner peripheral surface thereof is guided to the outer peripheral surface of the fifth fixed jig 106, Are set so as to be in direct contact with each other. 13, the lyser 83 can be bent in the form of a hook toward the other end of the rectifier piece 82. As a result, the second movable jig 107 can be bent in a hook shape toward the other end of the rectifier piece 82. [ Finally, the rectifier 8 of the present embodiment is formed through the above-described steps.

(Effects of the present embodiment)

The rectifier 8 is provided with a projecting portion (latching means) 83a for preventing the coil wire W wound on the distal end portion of the lyser 83 from being separated from the distal end portion of the lyser 83. [ 14, when the lyer 83 is pressed down by the second electrode bar 202 to the rectifier piece 82, the coil wire W is prevented from being broken by the projecting portion (engaging means) 83a It can be effectively prevented that it is separated from the leading end of the lyser 83 and separated. Therefore, as shown in FIG. 15, the lyser 83 can be formed short, and the axial length in which the lyser exists on the rectifier piece 82 after the fusing process can be shortened. As a result, the portion of the rectifier element 82 which is eroded by the lysers 83 in the axial direction length becomes smaller.

Therefore, the length in the axial direction in which the brush 3c contacts the rectifier piece 82 can be sufficiently secured. Furthermore, the axial length of the rectifier element 82 and the axial length of the rectifier main body 81 to which the rectifier element 82 is fixed can be shortened. As a result, the rectifier 8 can be downsized. Even when the wire diameter of the coil wire W is large, the provision of the protruding portion (engaging means) 83a prevents the coil wire 83 wound on the coil wire W Can be effectively prevented from deviating from the tip of the lyser 83. [

The projecting portion 83a is configured to protrude substantially integrally from the front end of the lyser 83 toward the rectifier piece 82. [ The projection 83a can be formed by integrally projecting the projection 83a from the lyser 83 by machining the lyser 83 itself without providing a separate component to the lyser 83 Thus reducing material and cost.

Further, the protruding portion 83a is formed by a direct-acting (pressing) process by the protruding portion forming process. Therefore, the projecting portion 83a can be formed by a simple and easy manufacturing method.

[Industrial Availability]

According to the rectifier, the length of the rectifier in the axial direction can be shortened, and a small rectifier can be provided.

[Description of Symbols]

1 Electric motor

2 housing

3 Brush device

4 magnets

6 Armature

7 Shaft

8 Rectifier

9 Armature core

81 Rectifier main part

82 rectifier

83 Liza

83a protruding portion (engaging means)

83b outer surface

83c corner

101 first fixing jig

102 second fixing jig

103 First movable jig

104 third fixing jig

105 fourth fixing jig

106 fifth fixing jig

107 Second movable jig

201 first electrode rod

202 Second electrode rod

W coil line

Claims (7)

A cylindrical rectifier main body portion formed of a resin,
A plurality of plate-shaped rectifier parts formed of a conductive material and fixedly arranged at the same pitch in the circumferential direction of the outer peripheral surface of the rectifier main part,
A plurality of rectifier parts formed integrally with one end of each of the plurality of rectifier parts, each of the rectifier parts being bent outwardly and projecting toward the other end of the rectifier part and being opposed to the rectifier part,
The rectifier for an electric motor,
Wherein the lyser has a rectangular cross-sectional shape and is tapered at both corners of the outer surface of the lyser, and a tip end portion of the lyser is integrally formed in the radial direction toward the rectifier element Wherein a step is formed on both the first surface opposed to the rectifier element and the second surface opposite to the first surface so that protrusions protruding from the first surface are formed. delete delete A cylindrical rectifier main body portion formed of a resin,
A plurality of plate-shaped rectifier parts formed of a conductive material and fixedly arranged at the same pitch in the circumferential direction of the outer peripheral surface of the rectifier main part,
A plurality of rectifier parts formed integrally with one end of each of the plurality of rectifier parts, each of the rectifier parts being bent outwardly and projecting toward the other end of the rectifier part and being opposed to the rectifier part,
The method comprising the steps of:
A ring member forming step of forming a ring member having a plurality of said lyzers extending radially outward in the radial direction at one end of the plate member,
A tapering process is performed on both edges of the outer surface of the plurality of lyers by using a fixing jig for inserting the ring member and a movable jig moving with respect to the fixing jig to sandwich a plurality of the lysers of the ring member, A molding step of forming the rectifier main body part inside the member,
A dividing step of dividing the ring member at the same pitch in the circumferential direction to form the rectifier element,
A first surface opposed to the rectifier element and a second surface opposed to the first surface are formed so as to protrude radially from the radially extending tip end of the lyser so as to integrally protrude radially toward the opposed rectifier element, A protrusion forming step of forming a step on both sides of the second surface, and
And a bending step of bending the lyser toward the rectifier element. delete An electric motor having a rectifier according to claim 1. 2. The apparatus according to claim 1, wherein a first step is formed on the first surface of the lyser so that the tip of the lyser protrudes compared to other portions, and the tip of the lyser is formed on the second surface of the lyser And the second step is provided so as to be recessed in comparison with the portion of the second step.

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