JP2010011673A - Commutator assembly and dc brush motor having the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent a solder from slipping at an early timing of solder melting, the amount of solder from becoming small, and a melting state from becoming insufficient by automatically guiding a tip portion of wire solder to a predetermined position of a tip portion of a riser part. <P>SOLUTION: A commutator assembly includes a commutator washer for fixing commutator segments on a commutator core, and a plurality of riser parts extending radially outward, which are respectively connected with the commutator segments. An electric noise control component having a central cut portion in a doughnut shape is disposed in proximity to the plurality of riser parts in a shaft axial direction on an outer peripheral side of the commutator washer. A recessed guide part for receiving the tip portion of the solder in a solder feed direction is integrally formed at the tip portion side of the riser part. The tip portion of the fed solder is brought into contact with the tip portion side of the heated riser, and each electrode of the electric noise control component is soldered to each of the corresponding riser parts. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a commutator assembly fixed on a rotor shaft and provided with an electric noise countermeasure component for eliminating a spark at an end, and a brushed DC motor having the assembly.

  A brushed DC motor supplies current to a rotor winding from a DC power source via a brush and a commutator with which the sliding contact is made. The windings of such a brushed DC motor are electrically connected by soldering both ends of the winding wound around each rotor magnetic core to the riser portion connected to each commutator piece. . Further, a varistor (disc varistor) for eliminating sparks is provided, and each electrode of the varistor is soldered to a corresponding riser portion.

  Conventionally, the joining method of such a riser part and an electric wire or a varistor assumes hand soldering, and the tip shape of the riser part has been considered so that the electric wire can be easily hooked, but using an automatic soldering device No particular consideration is given to feeding the solder. Normally, the shape of the tip of the riser is straight, and when solder is sent automatically using thread solder, the thread solder tip slips at the initial stage of solder melting, resulting in less solder or insufficient melting. This causes a problem that electrical and mechanical joining becomes insufficient.

  FIG. 8 is a view showing a conventional commutator assembly in which the tip shape of the riser portion is deformed (Patent Document 1). Each of the commutator pieces (three pieces) in contact with the brush is integrally formed with a riser portion so as to form an L shape and is arranged on the base. The tip of this riser part was pre-sliced, a slit was formed so that the two pieces were stepped in the axial direction, a coil wire was inserted into this slit, and the riser part was lightly caulked to hold the coil wire Thereafter, the coil wire is soldered. As a result, even when soldering is insufficient, it is possible to improve the reliability of electrical connection between the coil and the riser portion. However, if the electric wire is sandwiched, when the electric wire is entangled in the riser section, disconnection occurs, the tact of the winding process is delayed, and the structure and control of the winding machine are complicated. there's a possibility that. Moreover, consideration is not given to the bonding reliability between the riser portion and the varistor.

FIG. 9 is a diagram showing a modification of the tip shape of the riser portion according to another conventional technique (Patent Document 2). The commutator piece is mounted on a commutator base made of synthetic resin. The riser portion is continuously provided in a shape bent at a right angle to one end of the commutator piece. The riser portion has a coil winding riser portion extending outward and varistor laser welding riser portions on both sides thereof. In this way, by deforming the riser shape, varistors can be laser welded, but laser welding requires high component accuracy and requires expensive equipment. Become.
Japanese Utility Model Publication No. 3-66563 JP 2006-311717

  In the present invention, when soldering a riser part and an electrical noise countermeasure component (varistor or the like) or an electric wire using an automatic soldering apparatus, the yarn solder tip automatically fed is guided to a predetermined position on the riser tip. Accordingly, it is intended to prevent the solder from slipping, the amount of solder being reduced, or the state of insufficient melting at the initial stage of solder melting, thereby ensuring electrical and mechanical joining.

  The commutator assembly of the present invention is fixed on a rotor shaft of a brushed DC motor and includes an electric noise countermeasure component for eliminating a spark at an end. This commutator assembly is disposed on the outer periphery of a commutator core fixed on the rotor shaft, and is connected to a plurality of commutator pieces of a conductor from which current is guided through a brush from the outside, and each commutator piece. A plurality of risers extending radially outward. A concave guide portion is provided on the leading end side of the plurality of riser portions, and the electrical noise countermeasure component and the leading end side of the riser portion are connected by soldering.

  In order to receive the solder tip in the solder feeding direction, the guide portion is formed as a concave portion recessed in the solder feeding direction, or a plate-like member integrally formed on the side surface of the riser portion. A gap is formed between each riser section and the electrical noise countermeasure component by providing a step on the tip side of each of the risers, and the wire at the end of the winding is hooked in this gap, and the electrical noise countermeasure component is soldered. At the same time, the electric wire is soldered to the riser section. The width of the leading end side of the riser portion is widened and the leading end portion of the riser portion for soldering is heated by a non-contact type heating device.

  The brushed DC motor of the present invention is obtained by fixing the commutator assembly on a rotor shaft.

  According to the present invention, by stabilizing the solder trajectory automatically fed and improving the reliability of soldering, not only the reliability of the electrical and mechanical joining of the riser part and the electric wire, but also the riser part and the electric The joining reliability of noise countermeasure parts can also be improved. This makes it possible to use solder (flux) -free solder, which has been poor in workability in the past, eliminates solder grain generation, and makes it possible to eliminate the cleaning of the rotor.

  Hereinafter, the commutator assembly of the present invention will be described based on examples. FIG. 1 is a cross-sectional view of the entire upper half of a brushed DC motor including the commutator assembly of the present invention. Hereinafter, a brushed DC motor having a 4-pole field magnet and a 6-pole rotor magnetic pole will be described as an example. However, the commutator assembly of the present invention has a 2-pole field pole and a 3-pole rotor or more. It can be used in a brushed DC motor having a magnetic pole.

  The motor housing includes a motor case and a case lid that is fitted into the opening of the motor case. A magnet for a field pole is attached to the inner peripheral surface of a motor case pressed into a bottomed hollow cylinder with a metal material. The magnetic poles of the illustrated magnet are four poles magnetized in the radial direction, and S and N are alternately formed in the circumferential direction. A side surface of a metal motor case having a substantially constant plate thickness forms a yoke serving as a magnetic path of the magnet. The shaft of the rotor is supported by bearings provided at the center of the case lid and at the center of the bottom of the motor case. The rotor configured on the shaft has a rotor magnetic pole configuration including a magnetic pole core and a winding wound on the magnetic pole core. The commutator assembly is fixed on a shaft, and an electric noise countermeasure part (disc varistor) for eliminating sparks is provided at an end of the commutator assembly. The brush (a pair) in contact with the commutator piece is connected to an external terminal supported by the case lid, and power is supplied from the outside through the external terminal.

  2 is a view showing the rotor of the brushed DC motor shown in FIG. 1 taken out, and is a cross-sectional view (A) in which the upper half is cut, and a side view (B) viewed from the commutator side. 3 is a view showing the commutator assembly shown in FIG. 2 taken out and is a cross-sectional view of the upper half. As shown, the rotor configured on the shaft includes a rotor magnetic pole configuration including a magnetic pole core and a winding wound on the magnetic core, and a commutator assembly. The commutator assembly, which is a feature of the present invention, is fixed on a shaft, and is provided with a varistor (disc varistor) for eliminating sparks at an end thereof. A rotor magnetic pole side surface on the opposite side of the commutator assembly is provided with a bush and a washer so as to contact a bearing provided at the bottom of the motor case. In the following description, a commutator assembly that is assembled after separately forming a commutator piece, a commutator core, and a commutator washer will be described as an example, but the present invention integrally forms the commutator piece and the commutator core. The present invention can also be applied to a commutator assembly formed by

  The commutator assembly shown in FIG. 3 includes a resin commutator core fixed on a rotor shaft, and a conductor that is disposed on the outer periphery of the commutator core (main body) and through which a current is guided from the outside. A plurality of commutator pieces (illustrated as six), a commutator washer that fixes the commutator pieces on the commutator core, and a plurality of riser sections that are connected to the respective commutator pieces and extend radially outward. Composed. The riser portion shown in the figure is formed by bending and extending each commutator piece integrally outward in the radial direction. Then, a gap is formed between the riser portion and the varistor by providing a step, and the winding end portion is hooked (hooked) into this gap and soldered, so that the riser portion and the winding Not only is the end connected, but also the varistor electrode located on the side of the varistor on the riser side is soldered.

  The commutator core is integrally formed of a synthetic resin with a commutator core base that supports a radially extending riser portion from the back side, integrally with the commutator core body that supports the commutator piece. Further, positioning claws (illustrated as three) provided at the end integrally with the commutator core are fitted into holes provided corresponding to the magnetic pole core, so that the circumferential direction of the commutator assembly with respect to the magnetic pole core And positioning in the axial direction. The disk varistor having a donut-like shape with the center cut out is disposed adjacent to the riser portion in the shaft axial direction on the outer peripheral side of the commutator washer after winding. After the varistor is disposed, each electrode of the varistor is soldered to the corresponding riser portion.

  4A and 4B are diagrams for explaining the shape of the riser part and the connection between the riser part and the wire and the varistor at the winding end. FIG. 4A shows the riser part, and FIG. 4B shows the winding before the varistor is mounted. The state which hooked the electric wire used as a wire end part is shown, (C) is mounting | wearing with the varistor, and has shown in the state turned upside down with (B). As described above, a step is provided on the leading end side of the riser part, and a gap is formed between the varistor in the axial direction of the shaft, and the electric wire is hooked here and then soldered. In the case of soldering by an automatic soldering apparatus, the tip of the riser portion is heated by the heating device at the same time as the yarn solder is fed. At that time, it is necessary to feed the tip of the yarn solder to an appropriate position. As long as the heating device can heat the tip of the riser part, either a contact heating device using a soldering iron or ultrasonic waves, or a non-contact heating device using infrared, high frequency, laser, etc. Can be used. As shown in FIG. 4C, it is desirable to send the thread solder from the leading end side of the riser part to the vicinity of the center position in the width direction of the riser part, and at least the riser part width should not be deviated. This is achieved by a concave guide portion provided on the leading end side of the riser portion. In order to receive the solder tip in the solder feeding direction, the illustrated guide portion is formed by a concave portion in which the center of the riser portion tip surface is recessed in an arc shape. As a result, even if the relative positional relationship between the thread solder tip and the riser part is slightly deviated, the thread solder tip can be brought into contact with and fed into the tip side of the riser part. Solder melted by coming into contact with the heated riser portion tip flows so as to fill a gap between the riser portion and the varistor, and thereby solder the riser portion, the electric wire, and the varistor electrode.

  FIG. 5 is a diagram illustrating heating using a high-frequency electromagnetic heating device. As described above, either a contact-type or non-contact-type heating device can be used for soldering heating. However, when a high-frequency electromagnetic heating device is used, as shown in FIG. By widening the width on the side, even if there is some variation in the position of the riser part with respect to the heating device, it becomes possible to heat stably. In high frequency electromagnetic heating, a high frequency current generated by a high frequency oscillator is passed through an induction coil, and heat generated based on eddy current and hysteresis loss generated when a heating material (riser part) is excited by a magnetic field induced there is used. However, by expanding the width of the riser tip, even if the position of the riser is slightly deviated in the width direction, at least a part of the width direction is in the induced magnetic field, so that the heatable state is still maintained. can do.

  FIG. 6 is a diagram illustrating another example of the concave guide portion provided at the tip of the riser portion. In FIG. 6A, the leading end side of the riser portion is formed wide, and the guide portion is constituted by a rectangular concave portion provided on the leading end surface side. In FIG. 6B, a guide portion is constituted by a concave portion in which the leading end side of the riser portion having a constant width is recessed in an arc shape. Furthermore, various variations of the shape of the guide portion are conceivable, such as those in which the solder trajectory is regulated not only in the horizontal direction but also in the vertical direction, and shapes that are easy to press. Any of these guide portions can guide the automatically fed yarn solder to an appropriate position. As a result, it becomes possible to guide the thread solder near the front of the riser section, and the solder trajectory is stabilized.

  FIG. 7 is a diagram illustrating an example of a concave guide portion provided at the tip of a riser portion where a wire serving as a winding end portion is spot-welded. The riser tip end side is bent into a U-shape, and the winding tip end is hooked to the bottom, and then spot welding is performed. After spot welding by applying an electrode from the outside of the riser part, the riser part and the varistor electrode are soldered. In FIG. 7 (A), the concave guide part for appropriately guiding the thread solder is constituted by a plate-like member formed integrally with the riser part on both sides from the riser part tip side. As a result, the solder trajectory of the automatically fed solder is stabilized, and solder is deposited on the guide portion as shown by the dotted circle in the figure, so that the solder joint reliability is improved. Moreover, since the solder guide does not protrude greatly in the lateral direction, the winding property is not affected.

  In FIG. 7B, the concave guide part is formed only on one side in the riser part width direction. It is suitable when the thread solder is sent from an oblique direction as shown. (C) has the same shape as the guide portion shown in FIG. 4, but can also be used as a guide portion for soldering the varistor electrode to the leading end side of the riser portion where the winding end portion is spot welded. .

It is sectional drawing which cut | disconnected the upper half of the whole brushed DC motor containing the commutator assembly of this invention. It is a figure which takes out and shows the rotor of the brush DC motor shown in FIG. 1, and is sectional drawing (A) which cut | disconnected the upper half, and the side view (B) seen from the commutator side. FIG. 3 is a view showing the commutator assembly shown in FIG. It is a figure explaining the connection of a shape of a riser part, a riser part, a coil end, and a varistor, (A) shows a riser part, (B) is a state where a coil end was hooked before varistor mounting (C) shows a state in which a varistor is mounted and (B) is turned upside down. It is a figure explaining the heating using a high frequency electromagnetic heating apparatus. It is a figure which shows another example of the guide part provided in the riser part front-end | tip, (A) comprised the guide part by the rectangular-shaped recessed part provided in the front end surface side, (B) was dented in circular arc shape. The example which comprised the guide part by the recessed part is shown. It is a figure which shows the example of the guide part provided in the riser part front-end | tip which carried out the spot welding of the coil | winding edge part, (A) is comprised with the plate-shaped member which formed the guide part integrally with the riser part, (B) The guide part is formed only on one side in the riser part width direction, and (C) shows an example in which the guide part is formed by an arcuate recess. It is a figure which shows the commutator assembly by the prior art which changed the front-end | tip shape of a riser part. It is a figure which shows the modification of the front-end | tip shape of the riser part by another prior art.

Claims (8)

In a commutator assembly which is fixed on a rotor shaft of a brushed DC motor and has an electric noise countermeasure part for eliminating a spark at an end,
A plurality of conductor commutator pieces arranged on the outer periphery of a commutator core fixed on the rotor shaft and conducting current from the outside through a brush, and extending radially outwardly connected to the respective commutator pieces. A plurality of risers,
A concave guide part is provided on the tip side of the plurality of riser parts,
A commutator assembly comprising the electrical noise countermeasure component and the leading end side of the riser connected by soldering. 2. The guide portion according to claim 1, wherein the guide portion is a concave portion recessed in the solder feeding direction in order to receive the solder tip in the solder feeding direction, or is formed by a plate-like member integrally formed on a side surface of the leading end of the riser portion. The commutator assembly as described. A gap is formed between each of the plurality of riser portions and the electrical noise countermeasure component by providing a step, and the wire at the winding end is hooked into the clearance, and the electrical noise countermeasure component The commutator assembly according to claim 1, wherein the electric wire is soldered to the riser portion simultaneously with soldering. The commutator assembly according to claim 1, wherein an electric wire at a winding end is spot-welded to the riser portion. The commutator assembly according to claim 1, wherein the riser portion is formed by bending and extending radially outward with each commutator piece. The commutator assembly according to claim 1, wherein the width of the riser tip end side is widened and heating of the riser tip end portion for soldering is performed by a non-contact heating device. A brushed DC motor having the commutator assembly according to claim 1 fixed on a rotor shaft. In a commutator assembly which is fixed on a rotor shaft of a brushed DC motor and has an electric noise countermeasure part for eliminating a spark at an end,
A plurality of conductor commutator pieces arranged on the outer periphery of a commutator core fixed on the rotor shaft and conducting current from the outside through a brush, and extending radially outwardly connected to the respective commutator pieces. A plurality of risers,
A concave guide part is provided on the tip side of the plurality of riser parts,
A commutator piece including a riser portion for a commutator assembly, wherein the electrical noise countermeasure component and the leading end side of the riser portion are connected by soldering.

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