JPH09322484A - Commutator motor and manufacturing method thereof - Google Patents

Abstract

(57) [Abstract] [Problem] Even if the armature winding is thickened in response to higher input, the wire distance of the commutator hook is stably secured without increasing the outer diameter of the commutator. To do. An armature winding wound around an armature iron core and connected to a commutator, and a commutator piece on one side of a commutator, which is formed by annularly arranging the commutator pieces around a synthetic resin and insulatingly holding the commutator piece, In a commutator motor, which is integrally provided with a hook for connecting the armature winding, a peripheral surface of a hook root winding portion for armature winding provided on both sides of a root portion of the hook is a center. Since the left and right steps are formed differently in the line direction, the distance between the adjacent windings wound around the hook can be stably ensured.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a commutator motor used for rotary machines such as vacuum cleaners and electric tools, and a method for manufacturing the same.

[0002]

2. Description of the Related Art In recent years, commutator motors have tended to become smaller and have larger capacities, and the performance problems required for commutators used therein are also required to be smaller, more efficient, and more powerful.
In particular, commutator motors used in electric vacuum cleaners are being rotated at high speeds in order to obtain high efficiency.

FIG. 17 is a cross-sectional view showing a commutator motor used in rotary equipment such as an electric vacuum cleaner and an electric tool, and FIG. 18 is a front cross-sectional view showing an armature of the commutator motor.
In the figure, 1 is a commutator, 2 is a commutator piece made of copper or copper alloy which is arranged and held in an annular shape around the outer circumference of the commutator 1, and 3 is a hook provided on one side of the commutator piece 2.
6 is an armature winding, 7 is an armature core, and 8 is an armature slot. A rotating shaft 9 supports the commutator 1 and the armature core 7 concentrically. An armature winding 6 which is wound while being housed in an armature slot 8 of an armature core 7 is connected to the hook 3. As shown in FIGS. 19 to 21, such a commutator 1 has an armature winding 6 which is wound while being housed in a slot 8 of an armature core 7 and is connected while being wound around the hook 3 in an α shape. It continues in succession to the next coil winding.

The hook 3 to which the armature winding 6 is wound and connected in an α shape as described above is formed by the manufacturing process shown in FIG. In the commutator 1 before processing, the commutator pieces 2 are aligned and fixed in parallel with the outer periphery of the synthetic resin portion 5, and the portion to be the hook 3 extends to one side by a desired length. In the commutator 1 having the above-described shape, first, both sides of a portion which becomes the hook 3 extended to a desired length on one side are scraped by a predetermined width by cutting with a circular rotary blade 10. At that time, the synthetic resin portion 5 is cut to a position where it bites slightly. After that, burr and shavings are removed by buffing, and then it is bent like a hook toward the outer peripheral side by bending and buffed again to complete the formation of the hook 3. As shown in FIG. 23, the hook 3 of the commutator 1 of the conventional commutator motor formed by the manufacturing process as described above has bulges 31 due to distortion on both sides of the hook bending portion.

Further, FIG. 24 shows, for example, Japanese Patent Laid-Open No. 7-298.
It is a top view which shows the commutator of the conventional commutator motor disclosed by the 565 publication. The commutator 1 is one in which a hook 3 provided on one side of a commutator piece 2 arranged and fixed in parallel with the outer periphery of a synthetic resin 5 is provided with a chamfer 4 at the base of the one side. As a result, the line distance of the armature winding 6 between the adjacent hooks 3 of the commutator 1 can be stably secured,
It is disclosed that the thick wire can be wound and the efficiency of the electric motor can be improved.

[0006]

However, the hook of the commutator 1 of the conventional commutator motor formed by the manufacturing process in which both sides of the above-described commutator piece are cut and then bent. No. 3, since the width of the hook 3 bulges 31 due to strain on both sides of the bent portion of the hook and the hook interval is narrowed, it is difficult to secure a constant and stable distance, and the wire-to-wire distance after the winding is not constant. There is a problem of becoming stable.

Further, as illustrated in FIG. 24, the hook 3
Even if some corners of the surface of the root of the contacting armature winding 6 is chamfered 4, the width of the commutator hook 3 of the commutator motor used for the electric vacuum cleaner is 1 mm to 2 mm, and the thickness is also Since it is about 1 mm to 2 mm, the wire diameter is 0.5 to 0.
When the 7 mmφ armature winding 6 is wound in an α-shape, the wire diameter is large and the rigidity of the winding is strong, so that the armature winding 6 can project on both sides of the hook 3 to secure the desired wire-to-wire distance. Can not. Therefore, it is effective for a wire having a relatively small wire diameter of 0.45 mmφ or less, but for a wire having a wire diameter of 0.5 mmφ or more, the wire-to-wire distance at the hook portion of the armature winding is It becomes difficult to secure a stable value, and it is necessary to visually check the distance between the lines after connection, resulting in a decrease in productivity due to an increase in man-hours. Further, if the chamfering amount and chamfering angle of the chamfered portion 15 are increased, the contact area at the time of fusing becomes small, so that a large current concentrates and flows, and the hook 3 may be damaged. Further, when the hook 3 becomes thin, there is a problem that the hook 3 is deformed by the tension of the winding machine during winding.

Further, if the chamfering amount and chamfering angle of the chamfered portion are increased in order to secure the distance between the wires, the winding holding connected to the chamfered portion becomes unstable, and the winding position varies and is not constant. Further, when the hook width is made narrow, there arise problems that the hook is deformed by the tension of the winding machine during winding, and the hook is damaged by a large current during fusing. Therefore, it was necessary to increase the outer diameter of the commutator in order to wind the thick wire.

Further, a commutator of high input / high rotation speed specification usually adopts a data bar system in which the shape of a commutator piece can be complicated. This is a method in which a copper material drawn into the cross-sectional shape of a commutator piece is cut, rolled into a predetermined number of pieces, fixed with a band, and molded with a synthetic resin. This method is suitable for commutator motors for vacuum cleaners, etc. that have severe usage conditions. In this method, the hook bending process is performed after the hook cutting process and the cutting process of the root winding portion of the hook. However, even if the cutting process is performed with high accuracy, the commutator made of copper is used for the subsequent hook bending process. Since there is a possibility that variations in dimensions due to an increase in hook width may occur due to strain due to plastic deformation of one piece, a stable inter-hook dimension cannot be ensured, and the inter-wire distance after winding is unstable.

The present invention has been made in order to solve the above-mentioned problems, and the wire distance of the commutator hook can be stably secured without increasing the outer diameter of the commutator, and the armature winding can be secured. An object of the present invention is to provide a commutator motor and a method for manufacturing the same, which can achieve high efficiency by adopting a thick wire.

[0011]

A commutator motor according to the present invention comprises an armature winding connected to a commutator wound around an armature core, and a commutator piece arranged in a ring around a synthetic resin. In a commutator motor, which is provided integrally with the commutator piece on one side of a commutator that is insulated and held, and a hook that connects the armature winding, an electric machine provided on both sides of a root portion of the hook. The outer peripheral surface of the base winding portion of the hook for the subsidiary winding is formed with steps of different heights on the left and right sides.

Further, the outer peripheral surfaces of the hook root winding portion for the armature winding formed on both sides of the root portion of the hook are left and right and have a height (t) equal to or smaller than the wire diameter (D) of the armature winding. A step is formed.

Further, the outer peripheral surfaces of the hook root winding portions for armature windings formed on both sides of the root portion of the hook are formed with steps of different heights between adjacent commutators in the center line direction. Is.

Further, the outer peripheral surface of the hook root winding portion for armature winding formed on both sides of the root portion of the hook forms a step along a straight line inclined from one of left and right to the other in the center line direction. It has been done.

Further, the armature winding connected to the commutator wound around the armature core, and one side of the commutator in which the commutator pieces are annularly arranged around the synthetic resin and are insulated and held, In a method of manufacturing a commutator motor, which is provided integrally with a child piece and has a hook that connects the armature winding, the hook is formed in a step of bending the commutator piece and then cutting both sides thereof. It is a manufacturing method of a commutator motor.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1. 1 to 2 are enlarged views showing the main configuration of the commutator according to the first embodiment of the present invention, and FIGS. 3 to 5 show the overall configuration of the commutator according to the first embodiment of the present invention. In the figure, reference numeral 1 is a commutator, 2 is a commutator piece, which is made of a good conductor made of copper or copper alloy and is arranged around the commutator 1 in a ring shape in parallel with the axial direction. 3 is a hook, commutator 1
Both sides of the commutator piece 2 extending to one side of are processed into thin pieces by cutting, and then bent into a hand shape of a key. 4 is a winding winding portion provided on both sides of the root of the hook 3,
One step 11 having lower left and right outer peripheral surfaces of the root is formed at a step having a different height in the center line direction with respect to the other step 12. Reference numeral 5 denotes a synthetic resin portion, which is made of phenol resin or the like and forms the core portion of the commutator 1. Reference numeral 6 denotes an armature winding, which is wound around the hook 3 of the commutator 1 wound around the armature iron core in an α-shape and connected, and continues to the next coil winding. The armature winding 6 wound around the hook 3 in the shape of α is connected to the hook 3 by heat welding by pressing while applying pressure. At this time, the synthetic resin portion 5 serves as a pedestal that prevents the root of the hook 3 from being deformed. The winding winding portion 4 and the synthetic resin portion 5 forming the roots on both sides of the hook 3 are cut at the same time as the cutting work for shaping the hook 3, and are lowered in the axial direction. Reference numeral 9 denotes a rotary shaft, to which the commutator 1 is press-fitted and fixed.

In the commutator 1 thus constructed, the synthetic resin portion 5 is hooked when the armature winding 6 and the commutator hook 3 are connected by heat welding by fusing while pressing the armature winding 6. It becomes a cradle that prevents the deformation of the root of No. 3. Further, since the winding winding portion 4 and the synthetic resin portion 5 are processed to be low in the axial direction by cutting during the shape processing of the hook 3, they do not hinder the connection of the armature winding 6. Further, since the outer peripheral surface of the hook base winding portion 4 is provided with steps of different heights on the left and right sides, it is possible to stably secure the line distance without reducing the cross-sectional area of the hook 3. Especially, it is easy to secure the distance between wires even if the winding diameter becomes thicker.
Since it is not necessary to visually check the distance between lines after connection, productivity can be improved by reducing the number of steps.

Embodiment 2. In the first embodiment, the outer peripheral surface of the hook root winding portion 4 for the armature winding, which is provided on both sides of the root portion of the hook 3, is configured so as to form a step having different heights on the left and right sides. As shown in FIG. 7, the difference (t) between the step 11 on one side of the winding winding portion 4 at the base of the hook 3 and the step 12 on the other side is defined as the wire diameter (Dmmφ) of the armature winding 6. With the above configuration, there is a large difference in the height of the armature winding 6 that sandwiches the hook 3, and a more stable line distance can be secured. The contact length between the root winding part 4 of the hook and the armature winding 6 is also increased, and a large current concentrates and flows when the heat welding connection by fusing is performed.
Can be prevented from being damaged or the hook 3 can be deformed,
Its soundness can be increased.

Embodiment 3 8 to 13 show Embodiment 3 of the present invention, in which one of the outer peripheral surfaces of the hook root winding portion 4 for armature winding formed on both sides of the root portion of the hook 3 is formed to be high. With respect to the step 13, the other step 14 in which the outer peripheral surface of the hook root winding part 4 for armature winding is formed low is provided on both sides of the root part of the adjacent hook 3.
The steps are formed with different heights. That is, the winding winding portion 4 at the base of the hook 3 has the same level difference on the left and right sides of each hook 3 so that the adjacent hooks 3 have different level differences. As a result, the distance between the wires can be stably secured without reducing the cross-sectional area of the hook 3. In particular, it is easy to secure the wire-to-wire distance even if the winding diameter is thick, and it is not necessary to visually check the wire-to-wire distance after connection, and productivity can be improved by reducing the number of steps.

Embodiment 4 14 to 15 show Embodiment 4 of the present invention, in which the outer peripheral surface of the hook root winding portion 4 for armature winding formed on both sides of the root portion of the hook 3 is formed lower in the center line direction. The left and right steps are the one step 1
It is assumed that the straight line is inclined from 5 toward the other step 16. As a result, the height of the armature winding 6 sandwiching the hook 3 changes from one step 15 to the other step 16 while smoothly guiding from a high position to a low position. Therefore, since an unreasonable external force is not applied to the hook 3 and the winding property can be improved, the winding can always be stably performed. Especially,
Even if the wire diameter becomes thick, it is easy to secure the distance between the wires, and it is not necessary to visually check the distance between the wires after connection, and the productivity can be improved by reducing the number of steps.

Embodiment 5 16 is a process diagram of a commutator showing a fifth embodiment of the present invention. The unprocessed commutator 1 has a commutator piece 2 which is annularly arranged around the synthetic resin portion 5 and is insulated and held, and extends to one side by a desired length. First, the hook 3 extending to a desired length on one side is bent into a hook-like hand toward the outer peripheral side by bending. After that, both sides of the portion that has become the hook 3 are cut by the circular rotary blade 10 so as to have a predetermined interval, including the width expansion of the hook 3 due to distortion, and adjacent parts are kept at a constant interval. After forming the hook 3 having a predetermined shape, a buff is applied to finish the removal of burrs and shavings. As a result, it is possible to secure a stable hook-to-hook dimension at a constant interval, which is also a favorable condition for securing the wire-to-wire distance after winding. Moreover, since the intermediate buffing can be omitted, the manufacturing process can be shortened.

[0022]

As described above, according to the present invention, since a step is provided at the left and right heights of the winding winding portion at the base of the hook of each commutator piece, the armature with the hook sandwiched is provided. A difference occurs in the height of the windings, and this height difference can always be stably obtained, so that the line distance can be secured. In particular, even if the wire diameter becomes thick, it is easy to secure the distance between the wires, and it is not necessary to visually check the distance between the wires after connection, and the productivity can be improved by reducing the number of steps.

Further, the height difference (t) between the left and right sides of the winding winding portion at the base of the hook is set to be equal to or larger than the wire diameter (Dφ) of the armature winding, and the height difference between the armature windings sandwiching the hook is set. It is possible to secure a stable distance between lines by configuring so that
In particular, it is possible to easily secure the distance between the wires even if the wire diameter becomes thick, and during the heat welding connection by fusing, a large current flows and the hook 3 is damaged or the hook 3 is deformed. It is possible to prevent the occurrence of damage and improve its soundness, so that it is not necessary to visually check the distance between the lines after connection, and the productivity can be improved by reducing the number of processes.

Furthermore, since the winding winding portion at the base of the hook is made to have a step difference between adjacent hooks so that there is a difference in the height of the armature winding sandwiching the hook, the step is always Since it occurs stably, the distance between lines can be secured. The α-shaped winding of the armature winding is performed reasonably, and in particular, it is easy to secure the distance between wires even if the wire diameter becomes thick, and it is not necessary to visually check the distance between wires after connection. It also improves productivity by reducing processes.

Further, by making the left and right steps in which the outer peripheral surface of the hook base winding portion 4 is formed lower along the straight line inclined from one step 15 to the other step 16, the step is always made. It is stably generated, and winding can be performed along the inclined surface without applying an unreasonable external force, so that the winding property can be improved. In particular, it is easy to secure the distance between the lines even if the diameter of the wire becomes thicker, it is not necessary to visually check the distance between the lines after connection, and the productivity can be improved by reducing the steps.

Further, since the process of cutting the hook and the winding portion of the root wire of the hook is performed after the bending of the commutator hook portion, the influence of the change in the spacing due to the bending strain can be eliminated, so that the stable inter-hook dimension can be obtained. It is possible to secure the distance, which is a good condition for securing the distance between the wires after the winding. Since the intermediate buffing can be omitted, the manufacturing process can be shortened.

[Brief description of drawings]

FIG. 1 is an enlarged view showing a main configuration of a commutator motor according to a first embodiment of the present invention.

FIG. 2 is a partial cross-sectional view taken along the line II-II of FIG.

FIG. 3 is a top view showing the commutator according to the first embodiment of the present invention.

FIG. 4 is a side view showing the commutator according to the first embodiment of the present invention.

5 is a bottom view showing a VV arrow of FIG. 4. FIG.

FIG. 6 is an enlarged view showing a main configuration of a commutator motor according to a second embodiment of the present invention.

FIG. 7 is a partial cross-sectional view taken along the line IIV-IIV of FIG.

FIG. 8 is a top view showing a commutator according to a third embodiment of the present invention.

FIG. 9 is a side view showing a commutator according to a third embodiment of the present invention.

FIG. 10 is a bottom view showing an arrow XX in FIG.

FIG. 11 is an enlarged view showing a main part configuration of a third embodiment of the present invention.

FIG. 12 is a partial cross-sectional view showing the arrow XII-XII in FIG.

FIG. 13 is a partial cross-sectional view showing a line XIII-XIII in FIG.

FIG. 14 is an enlarged view showing a main configuration of a fourth embodiment of the present invention.

FIG. 15 is a partial cross-sectional view taken along the line XV-XV of FIG.

FIG. 16 is a process diagram of a commutator showing a fifth embodiment of the present invention.

FIG. 17 is a sectional view showing a commutator motor.

FIG. 18 is a partial front sectional view showing an armature of a commutator motor.

FIG. 19 is a top view showing a commutator of a conventional commutator motor.

FIG. 20 is a side view showing a commutator of a conventional commutator motor.

FIG. 21 is a bottom view showing a commutator of a conventional commutator motor.

FIG. 22 is a processing step diagram showing a commutator of a conventional commutator motor.

FIG. 23 is an enlarged view showing a hook of a commutator of a conventional commutator motor.

FIG. 24 is a process diagram of a commutator showing a conventional commutator motor.

[Explanation of symbols]

1 commutator, 2 commutator piece, 3 hook, 4 hook root winding winding part, 5 synthetic resin part, 6 armature winding, 7
Armature iron core, 8 armature slots, 9 rotating shafts, 10
Tool (cutting blade), 11 One step, 12 The other step, 13 One step, 14 The other step, 15 One step, 16 The other step.

Claims (5)

[Claims] 1. An armature winding connected to a commutator wound around an armature iron core, and a commutator formed by annularly arranging the commutator pieces around a synthetic resin and insulatingly holding the commutator. In a commutator motor provided integrally with an armature piece and having a hook for connecting the armature winding, an outer peripheral surface of a hook root winding portion for armature winding provided on both sides of a root portion of the hook. The commutator motor is characterized in that steps are formed with different heights on the left and right sides. 2. An outer peripheral surface of a hook root winding portion for armature winding formed on both sides of the root portion of the hook has a height (t) equal to or less than a wire diameter (D) of the armature winding on the left and right. The commutator motor according to claim 1, wherein a step is formed. 3. An outer peripheral surface of a hook base winding portion for armature winding formed on both sides of the base portion of the hook is formed with a step having different heights between adjacent commutators in a center line direction. The commutator motor according to claim 1, wherein: 4. An outer peripheral surface of a hook root winding portion for armature winding formed on both sides of a root portion of the hook forms a step along a straight line inclined from the left to the right in the center line direction to the other. The commutator motor according to claim 1, wherein the commutator motor is provided. 5. An armature winding connected to a commutator wound around an armature core, and a commutator formed by annularly arranging the commutator pieces around a synthetic resin and insulatingly holding the commutator. In a method of manufacturing a commutator motor, which is provided integrally with a child piece and has a hook that connects the armature winding, the hook is formed in a step of bending the commutator piece and then cutting both sides thereof. A method for manufacturing a commutator motor, comprising: