JPS5947545B2 - Manufacturing method for cup-shaped ironless armature - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a cup-shaped ironless armature.

To manufacture a conventional cup-shaped coreless armature, first, the armature winding is wound using 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. Also, because it is a vacuum casting process, there are areas where the resin is not injected, such as air bubbles, which weakens the strength of the armature and causes quality problems. Ta.

As a means to improve the conventional method, the armature winding assembly is inserted into a mold, and semi-cured resin is heated from the outside by a gate provided at the cup opening or bottom outer periphery of the cup-shaped armature. A method of pressurized injection has been proposed.

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 Since resin is injected under pressure, if the wire diameter of the armature winding is small, it will not be able to withstand the injection pressure of the resin, and the winding may become deformed, or the wires leading to the commutator may break, or the winding may become damaged. 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 disk-shaped resin plate made by kneading the A-stage (main resin) thermosetting resin with additives is placed on the heated A mold 3, and the above-mentioned Commutator 5 and shaft 6 with armature winding 1 connected to lead wire 2
B mold T is inserted together and heated from above.
Insert.

As the B mold γ is inserted, the armature winding 1 is shaped to a predetermined size.

Next, before the writing B mold 1 is completely inserted to the predetermined position, the C mold 8 is pushed up from below to shape the coil end of the cup opening, and the B mold 7 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 wetting the armature winding and sliding it.

Hold the above condition for several minutes, and after the resin has hardened,
The B mold γ is removed and the completed armature as shown in FIG. 3 is taken out.

Note that 9 is a protective cap provided to prevent the resin from adhering to the undercut portion and outer periphery of the commutator, and 10 is a cut groove for storing excess resin flowing out from the space.

In the above embodiment, the resin plate 4 is provided between the A mold 3 and the cup bottom of the armature winding 1, but the same result can be achieved even if the resin plate 4 is provided between the cup bottom of the armature winding and the B mold 7. Needless to say.

Further, although the above embodiment uses A-stage resin, B-stage (semi-cured) resin may be used in order 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 resin injection were carried out simultaneously in the same mold, but it goes without saying that they may be carried out in separate molds, and the shaft etc. can be shaped as needed. It may be inserted and fixed after the resin hardens.

As described above, a disc made of thermosetting resin is placed at the bottom of the cup of a winding mold, and an armature with a shaft commutator attached is placed inside a heating mold with grooves on the outer periphery of the lower part. The winding is shaped by inserting the winding and tightening the mold from the top and bottom, and as soon as the shaping is almost completed, the heated and softened resin flows into the winding and hardens, so when the mold is opened, the resin hardens. It becomes possible to take out the armature.

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

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

Furthermore, the cost of equipment and molds will also be significantly lower.

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

This 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 smoothing it, and the winding is fixed with the resin in a short time, making it easy to work and preventing shorts, breaks, and bends in the armature winding. No total heat is generated.

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 The excess resin is collected in the groove provided on the outer periphery of the lower part of the cylindrical mold A, so even if the winding specifications are different or the amount of resin varies, the resin pressure remains constant in the same mold. It is possible to make a suitable armature.

[Brief explanation of the drawing]

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 FIG. 3 is a cup-shaped electric machine manufactured according to the present invention. It is a sectional view of a child. 1... Armature winding, 4... Resin plate, 5
... Commutator, 3, 7, 8 ... Mold, 1
0...Groove.

Claims (1)

[Claims] 1. The armature winding is wound a predetermined number of times to form 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, and A mold is inserted from above, and the resin of the molding resin member is heated and flowed into the cup-shaped space formed by the mold, and the resin is further hardened to fix the armature winding. A method for manufacturing a cup-shaped ironless armature, characterized in that a groove is provided on the lower outer periphery of a cylindrical mold provided inside the cup-shaped space.