JPS6048982B2 - How to connect commutator and conductor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for connecting a commutator and a conductor, which are mainly used in rotating electric machines such as starters that rotate at high speed and have a high temperature rise, and in particular, a method for connecting a conductor to a commutator when the conductor has a heat-resistant insulating film. The present invention relates to a wiring method for electrically and mechanically coupling the wires.

Conventionally, various methods of connecting commutators and conductors in rotating electric machines have been developed and put into practical use.

However, in recent years, with the remarkable development of electrical insulation technology, it has become possible to rotate at high speed, like a starter, and the temperature f low→
←,, oi±-yoyo, date [, ゛, 1, zu 1, yu , は 1 item] As a countermeasure for problems such as +kR73L, heat-resistant insulation coatings such as polyamide-imide resin coatings that can withstand high temperatures are used as conductor insulation coatings. Insulating films have come to be used, and when using a conductor with such a heat-resistant insulating film, when the conductor is connected to a commutator using a well-known method, there is always a good relationship between the conductor and the commutator. Difficult to obtain electrical and mechanical connections.

In other words, in the generally well-known brazing method, in which a conductor is joined to a commutator using a low-melting material such as solder, the heat-resistant insulating film described above remains between the commutator and the conductor, and the brazing material Electrical and mechanical coupling between the two occurs only to a small extent.

In addition, the so-called fusing method, in which a commutator and a conductor are metallurgically joined by pressurization and electrical resistance heating, is one of the well-known wiring methods and is praised for its high efficiency. Even with this electric resistance heating, the aforementioned heat-resistant insulating film cannot be removed satisfactorily. However, due to the above-mentioned problems, if the heat-resistant insulating coating is removed in advance at the location where the conductor is to be connected, and then the above-mentioned methods are implemented, the work becomes complicated and requires a large number of man-hours, resulting in economical costs for the student. It is.

Therefore, the challenge for those skilled in the art is how to economically, electrically and mechanically firmly connect a conductor having a heat-resistant insulating coating to a commutator.

The present invention solves the above problems by skillfully utilizing a fusing process to break the heat-resistant insulation coating of the conductor, thereby economically obtaining good electrical and mechanical coupling between the conductor and the commutator. This is the purpose.

According to the present invention, protrusions are provided in advance at the conductor and the fusing location in the conductive portion of the commutator, and the protrusions are bitten into the conductor when pressurizing the fusing.

As a result, the heat-resistant insulating coating of the conductor is broken and the conductor is reliably electrically and mechanically coupled to the commutator at the protruding portion. The present invention also provides a commutator (copper commutator) in which the conductive part is made of an electrically conductive material based on copper, and a conductor in which the core wire is made of an electrically conductive material based on aluminum, which is soft and has a lower melting point than copper. (aluminum wire)
By using a combination of a copper commutator and an aluminum wire, the protrusions provided on the commutator easily bite into the conductor, making it possible to obtain even better electrical and mechanical connection.

In addition, aluminum wires are cheaper than copper wires and can reduce costs. The present invention will be described below with reference to embodiments shown in the drawings.

In Fig. 1, the rotor R of a rotating electrical machine such as a starter
In this case, the brush 2 is in sliding contact with the rotating shaft 1. The commutator 3 and the armature coil 4 are electrically and mechanically coupled by the method of the present invention, and the brush 2 is connected to the commutator. By slidingly contacting the surfaces of 3, a rectifying effect is achieved. As shown in FIGS. 2 and 3, the commutator 3 includes a plurality of pieces 6 forming a conductive part integrally formed with a riser part 6a, and a mold part 7 made of an insulating material that holds each piece 6 in an annular shape. The mold part 7
Each piece 6 is made of a copper-based electrically conductive material, and the molded part is formed by an integrally bent claw 6b. It is carried by 7.

A wire connection groove 9 is provided in the riser portion 6a of each piece 6, and two conductors 4a and 4b from the armature coil 4 are inserted into the groove 9 and arranged side by side. The electrical and mechanical connection between the two conductors 4a, 4b and the riser portion 6a achieves the electrical and mechanical connection between the commutator 3 and the armature coil 4, which should be noted here. That is each Kongkuta 4
a, 4b are composed of core wires 10a, 10b made of an aluminum-based electrically conductive material and heat-resistant insulating coatings 11a, 11b covering the outer peripheral surfaces of the core wires, and each wire connection groove 9 Protrusions 9a and 9b are provided on the bottom surface to fit into the respective conductors in accordance with the number of conductors. These seven protrusions 9a, 9b have a substantially triangular cross section, and have heat-resistant insulating films 11a, 1 with respect to conductors 4a, 4b.
1b and into the core wires 10a, 10b, and lies over the entire axial width of the groove 9. Therefore, in the state before fusion banging, the two conductors 4a and 4b are placed on the respective protrusions 9a and 9b within the groove 9, and a portion thereof protrudes from the groove 9 in the outer diameter direction. Thus, FIG. 3 shows a part of the fusing device.

A ground electrode (negative) 12 and a movable electrode 12 are schematically shown. The ground electrode 12 is in contact with the brush sliding surface of the piece 6 of the commutator 3, and the movable electrode 13 is slightly longer than the axial width of the riser portion 6a, or more than its circumferential width. The riser part 6 has a slightly shorter dimension relationship.
It is located above a. During fusing, the movable electrode 13 is pressed against the riser portion 6a of the piece 6.

Until the movable electrode 13 comes into contact with the outer circumferential surface of the riser portion 6a, there is no conduction between the electrodes 12 and 13, and only a pressing force is applied to the conductors 4a and 4b. Through this fusing pressurization process, as shown in FIG. 4, each conductor 4a, 4b is compressed within the groove 9, deformed to fit the inner wall of the groove 9, and each protrusion 9a, 9b at the bottom of the groove 9 is compressed.
is a heat-resistant insulating film 11a, for each conductor 4a, 4b.
11b and pierce the core wires 10a and 10b.

Furthermore, plastic deformation of the core wires 10a, 10b also causes local tearing of the heat-resistant insulating coatings 11a, 11b. Movable electrode 13
contact with the outer circumferential surface of the riser portion 6a of the piece 6 is because energization occurs between the electrodes 12 and 13, and the piece 6 and the conductor 4
Electrical resistance heating is applied to a and 4b. As a result, piece 6
The riser portion 6a and the conductors 4a, 4b are connected to the protrusion 9a.
, 9b and the core wires 10a, 10b are in a direct press-bond state, so that a diffusion zone is well formed at least at this boundary portion. The movable electrode 13 is pushed down until it finally bites into the riser part 6a of the piece 6, and therefore the riser part 6a
(7) Both shoulder portions near the entrance of the groove 9 deform inward and cover the shoulder portions of the conductors 4a and 4b0 on the groove wall side.

This overlapping portion is designated by the reference numeral 9c in FIG. Thus, the commutator 3 as shown in FIG.
A state of connection between the commutator and the conductors 4a and 4b can be obtained, and the commutator and the conductors 4a and 4b can be electrically and mechanically strongly connected.

In addition, as the conductors 4a, 4b, especially the core wires 10a, 1
Since 0b is made of an electrically conductive material based on aluminum, which is softer than copper, the protrusions 9a and 9b are made of copper, so that when the fusing is pressurized, the protrusions 9a and 9b are exposed to the heat-resistant insulating coating 11a, 11b and easily pierce the core wires 10a, 10b, making it possible to obtain a good bond.

Further, the shape of the protrusions 9a, 9b is not limited to the triangular shape shown in the illustrated example, and the protrusions 9a, 9b penetrate the heat-resistant insulating coatings 11a, 11b to the conductors 4a, 4b, and
Any shape may be used as long as it has the ability to bite into a and 10b.

Furthermore, the protrusions 9a and 9b can be easily formed when the groove 9 is manufactured. As described above, in the present invention, when a conductor having a heat-resistant insulating coating is connected to a conductive part of a commutator by fusing, a protrusion is provided in advance at a fusing location of the conductive part with the conmutator. , when the fusing is pressurized, the protrusion is bitten into the conductor, the protrusion is formed on the bottom surface of the connection groove of the commutator, and both shoulder portions near the grooving date are pressurized from the outer circumferential direction of the fusing. Since the protrusions are deformed inward and covered over the shoulders of the groove walls of the conductor, the protrusions can be easily formed when creating the grooves, and the protrusions bite into the conductor and simultaneously close the grooves just by applying pressure from the outer circumferential direction during fusing. Both shoulder portions near the inlet are covered with shoulder portions of the conductor on the groove wall side, whereby the commutator and the conductor are well connected at least at the protruding portion, and the commutator and the conductor are electrically and mechanically connected. To efficiently and economically obtain an electrical and mechanical bond between a commutator and a conductor, which has the excellent effect of being able to firmly bond and does not require the complicated process of removing a heat-resistant insulating coating in advance. It has the excellent effect of being able to

Furthermore, since the protrusions extend in the axial direction, the protrusions dig in along the axial direction of the conductor, and there is almost no decrease in strength at this part of the conductor. Not only the heat in the part, but also
The protrusion at the bottom of the groove mechanically cuts through the insulating coating of the conductor and at the same time becomes a new welding heat generating part, which in turn easily burns out the coating at the bottom of the groove far from both shoulders.
This has the excellent effect of ensuring a necessary and sufficient conduction area between the commutator and the conductor.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of a rotor wired using the wiring method according to the present invention, Figs. 2 to 5 are provided to explain the process of the method of the present invention, and Fig. 2 is a perspective view of a rotor wired by a wire connection method according to the present invention. A sectional view of the main parts showing the arrangement relationship, FIG. 3 is A- shown in the second figure.
FIG. 4 is a sectional view taken along line A, FIG. 4 is a cross-sectional view of a main part showing the state of the fusing when pressurized, and FIG. 5 is a perspective view showing the final connected state of the commutator and conductor. 3... Commutator, 4a, 4b... Conductor, 6... Piece forming a conductive part, 9a, 9b...
...Protrusion, 10a, 10b... Core wire, 11a,
11b...Heat-resistant insulation coating.

Claims (1)

[Claims] 1. In a method of electrically and mechanically connecting a conductor having a heat-resistant insulating film and a core wire made of aluminum to a conductive part of a copper-based commutator by fusing, the conductor of the conductive part A protrusion extending in the axial direction is provided in advance on the bottom surface of the connection groove, which is the fusing point with the conductor, and when pressure is applied from the circumferential direction of the fusing, the mechanical protrusion bites into the conductor, and both shoulders near the groove entrance are A method of connecting a commutator and a conductor, in which a portion of the conductor is deformed inward to cover the groove wall side shoulder portion of the conductor.