JPS5947543B2 - Manufacturing method of iron-free armature - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a coreless armature, in which a resin member for molding and parts constituting the armature, such as an armature winding, are placed in the same mold.

Conventionally, for example, in manufacturing a cup-shaped coreless armature, the armature winding is first wound with a winding machine to form a cup shape, and this winding is inserted into a shaping mold and shaped into a predetermined shape.

Thereafter, the lead wire of the winding to the commutator is connected to the riser of the commutator to which the shaft is attached, and the armature winding assembly is completed.

Next, the winding assembly is placed in a casting mold, and a resin solution such as epoxy is injected under reduced pressure and cured by heating to obtain a coreless armature.

However, in this method, the solution viscosity is very low and requires a very long time (more than 1 hour) for heating and curing, so many molds are required, a heating furnace is also required, and furthermore, resin injection is required. Otherwise, it is not suitable for mass production because it takes a lot of work time to remove particles, etc., and because it is cast under reduced pressure, subdivisions such as air bubbles that are not injected occur, which weakens the strength of the armature and causes quality problems. Ta.

As an improvement over the conventional method, the armature winding assembly is inserted into a mold and heated to a semi-cured state from the outside by a gate provided at the cup opening or bottom outer periphery of the cup-shaped armature. A method has been proposed in which resin is injected under pressure.

However, with this method, many molds can be made into small assemblies and injected all at once from one pot, and the curing time is only a few minutes, so mass production is much improved compared to the above-mentioned method, but the resin If the wire diameter of the armature winding is small, it will not be able to withstand the injection pressure of the resin, causing the winding to become deformed, or lead wires to the commutator to break, or the winding to There were problems such as short circuits because they were brought into close contact.

The present invention solves all the problems of the above conventional methods, and will be explained below with reference to the accompanying drawings.

First, as shown in FIG. 1, an armature winding 1 is provided, which includes a predetermined number of coil bundles made by winding a predetermined number of self-fused wires using a winding jig.

Note that 2 is a lead wire connected to the commutator.

Next, as shown in FIG. 2, a resin plate 4 made of A-stage (raw resin) thermosetting resin kneaded together with additives and configured into a disk shape is placed on the heated A mold 3, and from above the resin plate 4 is placed. The armature winding 1 is inserted together with the commutator 5 and shaft 6 connected to the lead wire 2, and the buffer member 1, which is made of a hollow thin rubber ring or the like and whose volume is reduced by pressurization, is inserted below the lead wire. Then, mold B 8 is heated from above.
Insert.

As the B mold 8 is inserted, the armature winding 1 is shaped into a predetermined size.

Next, before the B mold 8 is completely inserted to the predetermined position, the C mold 9 is pushed up from below to shape the coil end portion of the cup opening, and the B mold 8 is further inserted to the predetermined position. do.

At the same time, the resin of the resin plate 4 melts and fills the space formed by the molds A, B, and C while sliding over the armature winding.

Hold the above condition for several minutes, and after the resin has hardened,
2.B Remove the mold γ and take out the completed armature as shown in FIG.

Note that 10 is a protective cap provided to prevent the resin from adhering to the undercut portion and outer periphery of the commutator.

Although the above embodiments used A-stage resin, B-stage (semi-cured) resin may be used to shorten the curing time.

Of course, in order to further shorten the length, the resin plate may be preheated.

Furthermore, in the above embodiment, the shaping of the armature winding 1 and the injection of resin were carried out simultaneously in the same mold, but it goes without saying that the shaping of the armature winding 1 and the injection of resin may be carried out in separate molds, and the shaft etc. may be inserted and fixed after the resin has hardened.

Furthermore, the buffer member 1 may be provided at the cup opening, as shown in FIG.

As described above, a disk made of thermosetting resin and a buffer member whose volume is reduced by pressure are provided at the cup bottom (cup opening) of a winding mold, and inside the heating mold. The armature winding with the shaft commutator attached is inserted into the mold, and the mold is tightened from above and below to shape the winding.As soon as the shaping is almost completed, the heated and softened resin flows into the winding and hardens. When the mold is opened, the armature hardened with resin can be taken out.

As is clear from the above embodiments, the present invention provides the following effects.

1. Heat fluidization of the resin and shaping of the winding wire can be done in the same mold, and the resin fixation of the winding wire can be done at the same time, making it very efficient.

Furthermore, equipment and mold costs are also significantly lower.

2. In the conventional case, resin remained in runners, pots, etc., and the resin used was 20 to 30% of the product, but in the case of the present invention, the amount of resin that is unnecessary is zero.

The presence of the buffer member also reduces the amount of resin, which reduces the cost of the resin.

3. Resin is injected into the armature winding at a pressure slightly higher than normal pressure, wetting it and sliding it around, and the winding is fixed with the resin in a short time, making it easy to work with and preventing shorts and shorts in the armature winding.
No heat generation such as disconnection or bending occurs.

4. Since the conventional 2-3 steps are completed in 1 step, loss is greatly reduced and quality is stable.

5. A-stage (raw resin) can be used as the resin material, so it has good compatibility with the self-bonding coating or insulation coating applied to the electric wire, and the resin and the electric wire adhere well, making it suitable for electrical equipment. The child becomes strong.

6. Heating applied to the armature winding can be completed only once, reducing deterioration of the wire due to heating.

7. Since a buffer member whose volume decreases when pressurized is inserted, the same mold and resin plate can be used even if the amount of resin varies or the winding specifications change. The resin filling pressure does not increase beyond a certain level and becomes uniform.

It can also serve as protection for the armature winding.

[Brief explanation of drawings]

FIG. 1 is a perspective view of an armature winding used in the armature of the present invention, FIG. 2 is a sectional view showing a method of manufacturing the armature of the present invention, and FIGS. FIG. 3 is a sectional view of a cup-shaped armature. 1... Armature winding, 4... Resin plate, 5
... Commutator, 3, 8, 9 ... Mold, 7
...Buffer member.

Claims (1)

[Claims] 1. A predetermined number of turns of an armature winding are formed into a predetermined shape, and parts constituting the armature, including the winding and commutator, and a molding resin member that is solid at room temperature are placed on a heating mold. A mold is further inserted from above, and the resin of the molding resin member is heated and injected into the space formed by the mold, and the resin is hardened to form the armature winding. 1. A method of manufacturing a coreless armature for fixing an iron core armature, characterized in that a buffer member whose volume is reduced by pressurization is provided in the armature. 2. The coreless armature according to claim 1, wherein the buffer member is a member whose volume is reduced by pressurization and is provided at a lead wire connecting the armature winding to the commutator. manufacturing method. 3. The method of manufacturing a coreless armature according to claim 1, wherein the buffer member is provided at a corner of the armature or at an open end of the cup-shaped armature.