JP6473890B2 - Commutator and commutator motor provided with the commutator - Google Patents

Description

The present invention relates to a commutator commutator motor and its commutator motor comprises used such as domestic vacuum cleaners and automotive equipment.

In recent years, in a household vacuum cleaner and an electric motor that is used in automotive equipment, in particular, demand for high durability in a compact, low-cost commutator motor is increased.

Commutator motor, in Rukoto contacting the commutator segments and the sliding brush from a power source located outside of the commutator motor, for channeling commutator to current that rotates through the sliding brush Yes. In addition , since the electrical connection between the sliding brush and the commutator piece is performed by contact, a spark is generated at the contact portion, and the temperature tends to be high.

Also, the commutator segments, the thermal expansion coefficient between the insulating resin to mold holding the commutator segments are different. Therefore, by the heat effect of caused by the contact between the sliding brush and the commutator segments, each boundary surface, thermal strain tends to concentrate. Furthermore , since the rotor to which the commutator is attached rotates at high speed , centrifugal force acts on the commutator piece.

Thus, the boundary surface of thermal strain is concentrated there is 膨Ra Mukoto outward peeling. In some cases , the commutator piece partially swells, and irregularities occur on the outer peripheral surface of the commutator piece. Due to the generation of the unevenness, a spark generated between the commutator piece and the sliding brush becomes large, and finally ring fire is generated. As a result, abnormal wear and the sliding brush, because scattering and the like to put the commutator segments due to the damage of the insulating resin, the electric motor has a problem arises in that the stop.

As a prior art for solving the above problems, a commutator using a functionally gradient material is disclosed (for example, see Patent Document 1). The commutator, using FGM, by eliminating the interface between the insulating resin for molding the commutator pieces in commutator commutator, dispersing thermal stress, the centrifugal force by rotating at high speed Even if it acts, it had the effect that peeling and a crack were hard to produce.

JP-A-4-109847

However, the commutator according to Patent Document 1, cutting a conductive metal layer formed in a circular cylinder at a slit, since forming the commutator segments by dividing the hardness of the conductive metal layer is a conventional such that high compared to the oxygen-free copper material. Therefore, the slidability between the commutator piece and the sliding brush of the electric motor rotating at high speed is lowered, and it is considered that the spark is increased and the life is shortened.

As a remedy, the sliding brush of the conductive metal layer and the sliding which commutator motor, there is to be a resin-based brushes. However, in this configuration, although that has improved trackability by lowering the hardness of the sliding brush itself, there is a limit to the follow-up performance, in the commutator motor rotating at high speed, was frequently have led to occurrence of a spark.

Therefore, a technique is often employed in which the sliding brush is impregnated with sliding lubricating oil that improves the slidability between the commutator piece and the sliding brush and suppresses the generation of sparks . However , since the resin-based brush has a resin residual component inside, the inside of the resin brush can not be formed, and the sliding lubricating oil cannot be impregnated.

Furthermore, since the hardness of the conductive metal layer is higher than that of conventional oxygen-free copper materials, a plurality of grooves are provided in the commutator piece in connection with the connection method with the armature winding. Slit connection to bury and weld is generally used . Therefore , it is difficult to automate the connection with the commutator piece, and there is a problem in productivity.

Furthermore, to improve the performance of the commutator motor, with regard to thickening the armature windings, since the winding diameter can be connected by the outer diameter of the cylindrical and conductive metal layer is limited, the armature winding there is a limit to thickening the line. In order to solve this problem, when the outer diameter is increased, the commutator piece is heavier and the speed cannot be increased.

  The present invention has been made in order to solve the above-described problems, and has a long life by improving commutation of a commutator motor, a low price by improving productivity, and a high efficiency by thickening armature windings. An object of the present invention is to provide a commutator that realizes the optimization.

Commutator according to the present invention comprises in the radial direction of the cylindrical or columnar extending along the axis, and the sliding Dokinzoku layer, and the electrical insulating layer, and the inclined oblique function material.

The sliding metal layer is located on the outer peripheral side and is formed of a metal material having a metal layer porous. The electrical insulating layer is located on the inner peripheral side and is formed of a thermosetting resin having an insulating layer porous. The functionally gradient material is located between the sliding metal layer and the electrical insulating layer. The functionally gradient material includes a mixture of a metal material and a thermosetting resin. In the functionally gradient material, the content of the metal material decreases and the content of the thermosetting resin increases from the sliding metal layer toward the electrical insulating layer. In particular, the metal material is copper powder.

Thereby, the slidability which could not be impregnated in the resin-based brush can be improved, and the commutator can be impregnated with the sliding lubricating oil that suppresses the generation of sparks.

In the commutator according to the present invention, at least one of the metal layer porous and the insulating layer porous is impregnated with sliding lubricant. As a result, sliding lubricating oil is supplied to the sliding portion, and more stable slidability is secured under conditions of high speed rotation and high temperature.

The commutator according to the present invention further includes a winding connection part. Winding connection portion has a hook for electrically connecting the sliding metal layer and the armature winding. The winding connection part is formed of a metal bulk material. Thereby, the armature winding for the winding connection portion formed in a hook shape, by winding the α form, can be continuously connected. Thereafter, since the hook portion can be electrically connected by heat generation deformation and welding, productivity and quality in the connection process can be improved.

Furthermore, the commutator according to the present invention, have you to the winding connection portion, diameter of the portion for fixing the winding is larger than diameter of the sliding metal layer. With this configuration , the thickened armature winding can be wound and connected without increasing the outer diameter of the sliding metal layer that slides with the sliding brush . Thus, by reducing the winding resistance of the armature coils, it is possible to reduce the resistance loss, ing to achieve high efficiency of the commutator motor as a result.

Further, by using a discharge plasma sintering method, capable of producing inclined oblique functional material. Therefore, a clear boundary surface is not configured, and a microscopic void or the like generated on the boundary surface is not generated.

In addition, the commutator according to the present invention, the outer diameter dimension of the sliding metal layer sliding brush which has been employed in conventional commutator slides, when less than the radial dimension of the winding connection portion Does not need to be cut and removed from the outer diameter dimension that forms the hook to the dimension that the sliding brush slides . Therefore , the amount of conductive metal material used can be reduced, and an inexpensive commutator can be obtained.

  According to the present invention, the life of the commutator motor is increased by improving commutation, the productivity and quality of the armature winding are improved, and the efficiency is improved by increasing the thickness of the armature winding. Can be realized.

Half sectional view of commutator motor in Embodiment 1 of the present invention Half sectional view of commutator in Embodiment 1 of the present invention Half sectional view of commutator in embodiment 2 of the present invention

  Hereinafter, the present invention will be described with reference to the drawings. In addition, this invention is not limited by the following examples.

(Embodiment 1)
FIG. 1 is a half cross-sectional view of a commutator motor according to Embodiment 1 of the present invention. FIG. 2 is a half sectional view of the commutator according to Embodiment 1 of the present invention.

First, with reference to FIG. 1, the commutator motor is described which uses a commutator according to the first embodiment of the present invention. As shown in FIG. 1, a commutator motor 10 according to Embodiment 1 of the present invention is positioned so as to face a commutator 1 described later, an armature assembly 12 including the commutator 1, and the armature assembly 12. And a field assembly 11 to be provided.

Furthermore, it demonstrates in detail with drawing. A commutator motor 10 shown in FIG. 1 includes a field assembly 11 and an armature assembly 12. The field assembly 11 has a field core 11a and a field coil 11b. The field core 11a is formed by stacking magnetic steel plates enclosed in a cylindrical bracket 15 and held and fixed . Field coil 11b is Ru wound around the field core 11a. An armature assembly 12 is included in the center of the field assembly 11 . The armature assembly 12 includes an armature core 12a, an armature coil 12b, and the commutator 1. The armature core 12a is formed by laminating magnetic steel plates and the like . Armature coil 12b is Ru wound around the armature core 12a through the insulator 12d. Commutator 1, the armature winding 12c drawn out from the armature coil 12b is Ru are electrically connected.

The armature assembly 12 includes a central portion penetrates along the axis, a shaft 13 fixed by press-fitting the armature assembly 12 by a pair of bearings 14 press-fitted to the shaft 13, rotatably Is held fixed. Moreover, the commutator segment 2 of the commutator 1, a pair of sliding brushes 16 that are more configured to carbon or the like, in contact with a constant contact force by the brush spring 17 from the vertical (radial) direction commutator 1 Yes.

Here, when power is supplied to the commutator motor 10, a magnetic field is generated in the field coil 11 b of the field assembly 11 by the current flowing in the commutator motor 10, and the field core is based on the generated magnetic field. Magnetic flux will flow through 11a. Also, current flowing through the field coil 11b via the sliding brush 16 and the commutator 1, a current supplied to the armature coil 12b.

As a result, a rotational torque is generated in the rotational direction by the magnetic flux generated in the field assembly 11 and the current flowing through the armature coil 12b, and the armature assembly 12 rotates. Furthermore, the current supplied from the sliding brush 16 generates a rotational torque in a fixed direction with respect to the rotational direction due to the positional relationship of the armature coil 12b by the plurality of commutator pieces 2 constituting the commutator 1. The commutation is performed as follows . Therefore , the armature assembly 12 rotates stably.

Next, with reference to FIG. 2, to explain about the construction of the commutator. The commutator 1 according to the first embodiment of the present invention includes a sliding metal layer 3, an electrical insulating layer 5, and a radial direction of a cylinder or a column extending along an axis indicated by a one-dot chain line in the drawing. Functionally gradient material 4. The sliding metal layer 3, the electrical insulating layer 5, and the functionally gradient material 4 are disposed concentrically around the axis.

The sliding metal layer 3 is located on the outer peripheral side and is formed of a metal material having a metal layer porous. In particular, copper powder can be used as the metal material. The electric insulating layer 5 is formed of a thermosetting resin having an insulating layer porous located on the inner peripheral side . The functionally gradient material 4 is located between the sliding metal layer 3 and the electrical insulating layer 5. The functionally gradient material 4 includes a mixture of a metal material and a thermosetting resin. In the functionally gradient material 4, the content of the metal material decreases and the content of the thermosetting resin increases from the sliding metal layer 3 toward the electrical insulating layer 5.

  In particular, there are the following configurations as forms that exhibit remarkable effects. That is, in commutator 1 according to Embodiment 1 of the present invention, at least one of metal layer porous and insulating layer porous is impregnated with sliding lubricant.

Furthermore, it demonstrates in detail with drawing. As shown in FIG. 2 (a), the commutator 1, in the radial direction of the cylindrical or columnar, the sliding metal layer 3 on the outer peripheral side, an electrically insulating layer 5 on the inner peripheral side, the sliding metal layer 3 The functionally gradient material 4 is arranged concentrically between the electrical insulating layer 5 and the electrical insulating layer 5.

In addition, the sliding metal layer 3 located on the outer peripheral side in contact with the sliding brush ( 16 ) is composed of copper powder having a minute metal layer porous inside . The sliding metal layer 3 is formed by copper powder metallurgy. The electrical insulating layer 5 located on the inner peripheral side is made of a thermosetting resin such as a phenol material having a minute insulating layer porous therein . In any of the metal layer porous or insulating layer porous, the sliding lubricating oil is impregnated. The sliding lubricating oil, sliding between the sliding brush (16) and the sliding metal layer 3 is stabilized, rectified spark is suppressed.

Ri by the present arrangement, conductive heat generated by the centrifugal force and the commutator 1 itself generated by the rotation of the armature assembly 12, via the sliding metal layer 3 inside the metal layer porous positioned on the outer peripheral side, an electrically insulating The sliding lubricating oil impregnated in the layer 5 is deposited on the surface of the sliding metal layer 3.

Also, precipitation of the sliding lubricating oil, the commutator 1 is fast, rotating at a high temperature, even prone conditions as sliding and rectifier anxiety, in centrifugal force due to rotation of the commutator 1, more The sliding lubricating oil can be supplied. Therefore, more stable slidability is ensured under high speed rotation and high temperature conditions.

Note that the FGM, composition, tissue composition of different materials varies continuously, Ru der that the integrally combined material. Specifically, in the functionally gradient material 4, the metal material content decreases from the sliding metal layer 3 toward the electrical insulating layer 5, and the thermosetting resin content increases. Here, the functionally gradient material 4 is obtained by continuously changing the composition ratio of the copper powder metallurgy and the thermosetting resin. Specifically, the composition ratio of the copper powder and the thermosetting resin is such that the content of the copper powder decreases from the sliding metal layer 3 toward the electrical insulating layer 5, and the content of the thermosetting resin is To increase.

In particular, the FGM 4 can be produced using a discharge plasma sintering method. With the discharge plasma sintering method, the boundary surface of the FGM 4 are integrally formed by a discharge plasma sintering body. That is, since the functionally gradient material 4 is formed integrally , a clear boundary surface is formed between the sliding metal layer 3 and the functionally gradient material 4 and between the functionally gradient material 4 and the electrical insulating layer 5. forming Sarezu, such as micro voids occurring at the boundary surface have Na occur.

As another embodiment, as shown in FIG. 2 (b), the commutator (1) may be additionally provided with an oil supply mechanism 7 composed of felt or the like that impregnates more of the sliding lubricant. not good. If this configuration, it is possible to provide a sliding lubricating oil I prolonged longer period, it is possible to ensure the rectifying stability.

(Embodiment 2)
FIG. 3 is a half sectional view of the commutator according to the second embodiment of the present invention.

A commutator according to the second embodiment of the present invention will be described with reference to FIG. In addition, the same code | symbol is attached | subjected about the same component demonstrated in Embodiment 1 mentioned above, and the description is used.

  As shown in FIG. 3, the commutator (1) according to the first embodiment of the present invention further forms a hook 2b to which the armature winding 12c is electrically connected, and is formed of a metal bulk material. A line connection is provided.

Furthermore, it demonstrates in detail with drawing. As shown in FIG. 3, the commutator (1) is provided with a sliding metal layer 3 you contact with the sliding brush 16, and a winding connecting portion 2a hook 2b is formed. The sliding metal layer 3 is constituted by copper powder metallurgy. Winding connection portion 2a is electrically connected to armature winding 12c of commutator motor 10 through hook 2b. The winding connection part 2a is formed of a metal bulk material. The winding connection portion 2a holds and fixes the armature winding 12c . Root diameter d1 of hooks 2 b of the winding connection portion 2a, the sliding brush 16 is larger than the diameter d2 of the sliding metal layer 3 in contact.

According to this commutator segments 2 form, when connecting the commutator segments 2 armature winding 12c, against the armature winding 12c to hook 2 b, mechanical just wrapped α form Connection can be completed and continuous connection can be made.

Furthermore, in order to winding connection portion 2a is formed in the bulk material of the metal, by heating, bending deformation and welding the hook 2b, because it is possible to ensure a reliable electrical connection, connected or Productivity and quality in the connection process can be ensured.

Furthermore, as shown in FIG. 3 (b), by increasing the diameter d1 of the winding connection portion 2a armature winding 12c is Ru is fixed from diameter d2 of the sliding metal layer 3, full click 2 for the b, and when the armature winding 12c is wound in the form alpha, and spatial distance X of the winding coils adjacent a winding beginning or winding end portion of the winding coil, the adjacent winding coils the spatial distance Y, Ru can be easily ensured. Therefore , a thicker armature winding can be connected.

Since the present invention can stabilize the sliding brush during high-speed operation , it can be applied to electrical equipment that requires long life and high reliability , such as a household vacuum cleaner or an automobile equipment.

1 commutator 2 commutator segment 2a winding connection portion 2b hook <br/> 3 sliding metal layer 4 FGM 5 electrically insulating layer 10 commutator motor 12c armature winding 16 sliding brush

Claims (5)

In the radial direction of a cylinder or cylinder extending along the axis ,
Located outside circumference side, a sliding metal layer formed from a metal material having a metal layer porous,
Located on the inner peripheral side, an electrically insulating layer formed of a thermosetting resin having an insulating layer porous,
Located between the sliding metal layer and the electrical insulating layer , the metal material and the thermosetting resin are mixed and include the metal from the sliding metal layer toward the electrical insulating layer. A functionally gradient material in which the content of the thermosetting resin increases as the content of the material decreases ; and
Commutator with a. The commutator according to claim 1, wherein the metal material is copper powder . The metal layer porous and of the insulating layer porous, commutator according to any one of 請 Motomeko 1 or 2 impregnated with sliding lubricating oil to at least one. Furthermore, the commutator as described in any one of Claim 1 to 3 which comprises the hook to which an armature winding is electrically connected, and a winding connection part formed with a metal bulk material . The commutator according to any one of claims 1 to 4 ,
An armature assembly including the commutator;
A field assembly positioned opposite the armature assembly;
Commutator motor Ru equipped with.

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