Commutator structure and zero-gravity seat motor

Abstract

The invention relates to the technical field of commutators, and discloses a commutator structure and a zero-gravity seat motor, the commutator structure comprises a commutator main body, an insulating base body and an annular piezoresistor, a center hole is arranged in the commutator main body, and a plurality of wire hanging parts are arranged on one axial end surface of the commutator main body at intervals along the circumferential direction; the insulating base body is arranged in the center hole and used for insulating and isolating two adjacent wire hanging parts, a center shaft hole is formed in the insulating base body, a boss is arranged in the middle of the end face, deviating from the wire hanging parts, of the insulating base body in the axial direction in a protruding mode, and an annular mounting groove is defined by the outer wall of the boss, the inner wall of the commutator body and the end face, deviating from the wire hanging parts, of the insulating base body; according to the commutator structure, the mechanical performance of a motor provided with the commutator structure can be remarkably improved, and the high-silence and high-stability operation requirements of a zero-gravity seat are met.

Description

Technical Field

[0001] The present invention relates to the technical field of commutators, and in particular to a commutator structure and a zero-gravity seat motor. Background Art

[0002] With the development of modern science and technology, especially the rapid development and increasing popularity of new energy vehicles, people not only have higher and higher requirements for quietness in the cockpit, but also have higher and higher requirements for driving comfort. In order to meet the above requirements, zero-gravity seats are designed with the concept of simulating weightlessness. The seat angle and support points are adjusted by motors to evenly distribute the body's center of gravity, making the occupants seem to float in the air. Multi-point support is provided, such as comprehensive support for the head, back, buttocks and legs, ensuring that the weight of the whole body is evenly distributed, maintaining the natural curvature of the spine and the natural position of the legs, greatly improving comfort. Especially for long-term driving, the zero-gravity seat provides an ultimate comfortable experience, can perfectly fit the curve of the human body, and the material is soft, which effectively relieves the fatigue and stress caused by sitting for a long time.

[0003] At present, most motors used in zero-gravity seats are prone to produce sparks and electrical noise on the surface of the carbon brush and commutator during operation, which causes sparks to be generated when the motor is commutating, and causes strong pulse oscillations in the current and voltage of the motor, thus seriously affecting the normal operation of the zero-gravity seat. Therefore, there is an urgent need for a motor commutator that can meet the normal operation of the zero-gravity seat. Summary of the invention

[0004] In view of this, the present invention provides a commutator structure and a zero-gravity seat motor to solve the problem of lack of a motor commutator that can meet the normal operation of the zero-gravity seat.

[0005] In a first aspect, the present invention provides a commutator structure, which is applied to a zero-gravity chair motor, and the commutator structure comprises:

[0006] A commutator body is provided with a center hole therein, and a plurality of wire hanging parts are arranged at intervals along the circumferential direction on one end surface of the commutator body along the axial direction;

[0007] An insulating substrate is arranged in the center hole and is used to insulate and isolate the two adjacent wire hanging parts. A central axial hole is arranged in the insulating substrate. A boss is convexly arranged in the middle of the end face of the insulating substrate axially away from the wire hanging part. An annular mounting groove is formed between the outer wall of the boss, the inner wall of the commutator body and the end face of the insulating substrate away from the wire hanging part;

[0008] The annular varistor is embedded in the annular mounting groove and welded to the commutator body.

[0009] A commutator structure according to the present invention has at least the following beneficial effects:

[0010] A boss is provided at the middle part of one end of the insulating substrate away from the wire hanging part, and an annular mounting groove is formed between the outer wall of the boss, the inner wall of the commutator body and the end face of the insulating substrate. The annular mounting groove is used for embedding the annular varistor, and the bottom end of the annular varistor is supported and the inner and outer side walls of the annular varistor are limited. It only needs to weld the top end surface of the annular varistor axially away from the wire hanging part to the commutator body, that is, only one surface of the annular varistor needs to be welded to meet the requirement of fixed connection, and the welding process is simpler and the welding efficiency is improved. Because the annular varistor is welded and fixed in the end of the commutator body away from the hanging wire part, when the carbon brush contacts the outer surface of the commutator body and generates voltage during the operation of the motor equipped with the commutator structure, the annular varistor is turned on to generate heat and absorb the pulse voltage, thereby ensuring that there will be no commutation sparks to corrode the outer surface of the commutator body, reducing the wear on the outer surface of the commutator body to ensure the service life, and avoiding the generation of strong pulse oscillations and causing loud noise, thereby significantly improving the mechanical properties of the motor equipped with the commutator structure and meeting the requirements of normal operation of the zero-gravity seat; at the same time, by embedding the annular varistor in the end face of the commutator body away from the hanging wire part, it can not only avoid increasing the axial size of the commutator structure, but also avoid the annular varistor interfering with the action of winding the rotor on the hanging wire part.

[0011] In an optional implementation, the annular varistor is configured as an oxidized zinc-plated resistor.

[0012] In an optional embodiment, one end of the wire hanging portion axially away from the commutator body is folded outward to form a hook portion.

[0013] In an optional embodiment, the wire hanging portion is configured to be an inverted V shape, one end of the wire hanging portion connected to the commutator body is configured to be a first connecting segment, and the other end is configured to be a second connecting segment, and the angle between the arrangement direction of the second connecting segment and the axial direction is configured to be 25° to 35°.

[0014] In an optional embodiment, the boss extends axially away from one end of the wire hanging portion to outside the central hole.

[0015] In an optional embodiment, the commutator body is provided with a copper shell, the center hole is formed inside the copper shell, and the side wall of the copper shell is provided with an insulating groove corresponding to the circumferential clamping area of ​​each two adjacent hanging wire parts, and the insulating groove penetrates the copper shell along the axial direction.

[0016] In an optional implementation, the wire hanging portion and the copper shell are integrally stamped and formed.

[0017] In an optional embodiment, a hook body is provided at a position where the inner wall of the copper shell and each of the wire hanging parts are located in the same straight line along the axial direction, and the hook body extends along the radial direction of the copper shell toward the center of the copper shell; the upper end surface of the hook body along the axial direction is set as a first inclined surface, and the first inclined surface extends from the outside to the inside along the radial direction of the copper shell and is inclined upward; the lower end surface of the hook body along the axial direction is set as a second inclined surface, and the second inclined surface extends from the outside to the inside along the radial direction of the copper shell and is inclined downward.

[0018] In an optional implementation, the insulating substrate is configured as a bakelite body.

[0019] In a second aspect, the present invention further provides a zero-gravity chair motor, comprising the commutator structure provided in the first aspect above.

[0020] Because the zero-gravity chair motor includes a commutator structure, it has the same beneficial effects as the commutator structure and will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0022] Figure 1 It is a schematic diagram of an inverted three-dimensional structure of a commutator structure according to an embodiment of the present invention;

[0023] Figure 2 for Figure 1 Schematic diagram of the decomposition structure;

[0024] Figure 3 A schematic diagram of the main structure of a commutator structure according to an embodiment of the present invention;

[0025] Figure 4 It is a schematic diagram of the front view of a commutator body in a commutator structure according to an embodiment of the present invention.

[0026] Description of reference numerals:

[0027] 100-commutator body, 110-hanging wire part, 111-first connecting section, 112-second connecting section, 120-copper shell, 121-insulating groove, 130-hook body, 131-first inclined surface, 132-second inclined surface;

[0028] 200-insulating substrate, 210-central axis hole, 220-boss;

[0029] 300-annular mounting groove;

[0030] 400-Ring Varistor. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0032] In the description of this embodiment, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing this embodiment and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting this embodiment. In addition, the terms "first", "second", and "third" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0033] In the description of this embodiment, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this embodiment can be understood according to specific circumstances.

[0034] In the related art, when the motor used in the zero-gravity seat is in operation, the carbon brush and the commutator surface are prone to generate electric sparks and electrical noise, which causes the motor to generate sparks when commutating, and causes the current and voltage of the motor to generate strong pulse oscillations, thereby seriously affecting the normal operation of the zero-gravity seat. In order to solve the above technical defects, a commutator structure and a zero-gravity seat motor according to an embodiment of the present invention are provided.

[0035] Combine the following Figures 1 to 4 , describing an embodiment of the present invention.

[0036] According to a first aspect of an embodiment of the present invention, a commutator structure is provided, which is applied to a zero-gravity chair motor. The commutator structure includes a commutator body 100, an insulating substrate 200, and an annular varistor 400. A center hole is provided in the commutator body 100, and a plurality of wire hanging portions 110 are arranged at intervals along the circumferential direction on one end surface of the commutator body 100 along the axial direction; the insulating substrate 200 is provided in the center hole and is used to insulate and isolate two adjacent wire hanging portions 110. 10, a central axial hole 210 is provided in the insulating base 200, a boss 220 is provided in the middle of the end face of the insulating base 200 which is axially away from the wire hanging part 110, and an annular mounting groove 300 is formed between the outer wall of the boss 220, the inner wall of the commutator body 100 and the end face of the insulating base 200 which is away from the wire hanging part 110; the annular varistor 400 is embedded in the annular mounting groove 300 and welded to the commutator body 100. It can be understood that the axial direction mentioned in the text refers to Figure 1 Axial direction in.

[0037] The commutator structure of this embodiment is provided with a boss 220 at the middle part of one end of the insulating base 200 away from the hanging wire part 110, and the outer wall of the boss 220, the inner wall of the commutator body 100 and the insulating base 200 form an annular mounting groove 300, and the annular mounting groove 300 is used for the annular varistor 400 to be embedded, and the bottom end of the annular varistor 400 is abutted and supported, and the inner and outer side walls of the annular varistor 400 are limited. It is only necessary to weld the top end surface of the annular varistor 400 axially away from the hanging wire part 110 to the commutator body 100, that is, only one surface of the annular varistor 400 needs to be welded to meet the requirement of fixed connection, and the welding process is simpler and the welding efficiency is improved. Because the annular varistor 400 is welded and fixed in the end of the commutator body 100 away from the hanging part 110, when the carbon brush contacts the outer surface of the commutator body 100 and generates voltage during the operation of the motor equipped with the commutator structure of this embodiment, the annular varistor 400 is turned on to generate heat and absorb the pulse voltage, thereby ensuring that there will be no commutation sparks to corrode the outer surface of the commutator body 100, so that the outer surface of the commutator body 100 is less worn to ensure the service life, and avoids the generation of strong pulse oscillations and causing loud noise, thereby significantly improving the mechanical properties of the motor equipped with the commutator structure of this embodiment and meeting the high quietness and high stability operation requirements of the zero-gravity seat; at the same time, by embedding the annular varistor 400 in the end face of the commutator body 100 away from the hanging part 110, it can not only avoid increasing the axial size of the commutator structure of this embodiment, but also avoid the annular varistor 400 interfering with the action of winding the rotor winding on the hanging part 110.

[0038] It should be noted that in the related art, manufacturers of motors for zero-gravity seats purchase commutators from commutator manufacturers in order to solve the problem of sparks generated when the motors are commutated, and weld a varistor with a larger outer diameter than the commutator to the commutator on the production line of the motor assembly; since the motor manufacturer must install the annular varistor 400 alone, the motor production efficiency is reduced; the commutator structure in this embodiment embeds the annular varistor 400 in the annular mounting groove 300 during the manufacturing process, and can be connected to the commutator body 100 through single-sided welding; zero-gravity seat motor manufacturers can directly purchase the commutator structure of this embodiment, eliminating the welding process of the intermediate varistor and the commutator, improving the motor production efficiency, and saving about 10% of the cost.

[0039] Specifically, the annular varistor 400 is configured as an oxidized galvanized resistor. On the one hand, the oxidized galvanized resistor is not easy to crack when welded, and is convenient for being welded and fixedly connected in the annular mounting groove 300; on the other hand, the resistance value is large and the heat conduction is fast, which is convenient for eliminating the voltage generated by the contact between the carbon brush and the outer surface of the commutator body 100; on the third hand, the procurement cost is low, which further reduces the production cost of the motor equipped with the commutator structure of this embodiment and further improves the market competitiveness.

[0040] In some embodiments, one end of the wire hanging portion 110 axially away from the commutator body 100 is folded outward to form a hook portion. The hook portion is convenient for winding the rotor wire thereon and prevents it from falling off.

[0041] like Figure 3 As shown, specifically, the wire hanging portion 110 is arranged in an inverted V shape, one end of the wire hanging portion 110 connected to the commutator body 100 is arranged as a first connecting segment 111, and the other end is arranged as a second connecting segment 112, and the angle between the arrangement direction of the second connecting segment 112 and the axial direction is set to 25° to 35°; the wire hanging portion 110 arranged in an inverted V shape is convenient for winding more coils thereon, so that the commutator body 100 of the same outer diameter can achieve a higher power; at the same time, it is verified through field tests that the second connecting segment 112 with an inclination angle of 25° to 35° is easier to bend and easier to wind wire on it.

[0042] like Figure 3 As shown, in some embodiments, the boss 220 extends to the outside of the center hole at one end axially away from the wire hanging portion 110. The portion of the boss 220 extending to the outside of the center hole can, on the one hand, guide the installation of the annular varistor 400, so that the inner hole of the annular varistor 400 is firstly sleeved on the portion of the boss 220 extending to the outside of the center hole, and then pressed and embedded into the annular installation groove 300, which makes the assembly easier; on the other hand, it can increase the assembly connection area with the rotor and improve the stability of the assembly.

[0043] like Figures 1 to 3 As shown, in some embodiments, the commutator body 100 is provided with a copper shell 120, the center hole is formed inside the copper shell 120, and the side wall of the copper shell 120 is provided with an insulating groove 121 corresponding to the clamping area of ​​each adjacent two wire hanging parts 110 along the circumferential direction, and the insulating groove 121 penetrates the copper shell 120 along the axial direction. The commutator structure of this embodiment uses a cylindrical copper shell 120 with a central axis hole 210 as a raw material for preparing the commutator body 100, and the insulating groove 121 is obtained by milling. Compared with the insert-type commutator, it does not need to arrange the slices, which reduces the production process and can reduce the production cost.

[0044] Specifically, the wire hanging part 110 and the copper shell 120 are integrally stamped and formed; the welding process of the wire hanging part 110 and the copper shell 120 can be omitted, so the preparation process is further simplified and the processing cost is reduced.

[0045] like Figure 4 As shown, specifically, a hook body 130 is provided at a position where the inner wall of the copper shell 120 and each of the hanging wire parts 110 are located in the same straight line along the axial direction, and the hook body 130 extends along the radial direction of the copper shell 120 toward the center of the copper shell 120; the upper end surface of the hook body 130 along the axial direction is set as a first inclined surface 131, and the first inclined surface 131 extends from the outside to the inside along the radial direction of the copper shell 120, and is arranged to be inclined upward; the lower end surface of the hook body 130 along the axial direction is set as a second inclined surface 132, and the second inclined surface 132 extends from the outside to the inside along the radial direction of the copper shell 120, and is arranged to be inclined downward. In the process of obtaining the insulating base 200 by extrusion molding inside the copper shell 120, the inclined first inclined surface 131 and the second inclined surface 132 increase the radial and axial tension between the hook body 130 and the insulating base 200, thereby improving the stability of the multiple commutator segments made by milling the insulating grooves 121 on the copper shell 120, making them less likely to deform, and improving the service life of the commutator body 100 made by using the above copper shell 120. It should be noted that after all the insulating grooves 121 are milled on the copper shell 120, the copper shell 120 forms a plurality of commutator segments spaced apart in the circumferential direction, and each commutator segment is provided with a wire hanging portion 110 on the end face axially away from the annular varistor 400.

[0046] In some embodiments, the insulating matrix 200 is configured as a bakelite body. The insulating matrix 200 is made of bakelite and is formed inside the commutator body 100 by extrusion molding. The strength of bakelite is greater than that of plastic, so that the insulating matrix 200 is not prone to cracking when it is interference-fitted with the rotor shaft through the central shaft hole 210.

[0047] The method for preparing the commutator structure of this embodiment comprises the following steps:

[0048] Stamping: Selecting a copper shell 120 of a required size, and integrally stamping the copper shell 120 to obtain a wire hanging portion blank;

[0049] Degreasing and cleaning: degreasing and cleaning the copper shell 120 and the wire hanging part blank;

[0050] Drying: drying the cleaned copper shell 120 and the wire hanging part blank;

[0051] Extrusion molding: Extruding the copper shell 120 with bakelite as the raw material to form an insulating base 200 having a central axis hole 210;

[0052] Heat treatment: heat treatment is performed on the insulating substrate 200 to allow the bakelite material to fully undergo a cross-linking reaction, thereby removing moisture, gas, etc., releasing stress, and better ensuring dimensional stability and electrical performance;

[0053] Finishing: Finishing the copper shell 120, specifically, turning pins and milling all insulating grooves 121 on the copper shell 120, so that the copper shell 120 forms a plurality of commutator segments arranged at intervals along the circumferential direction; and finishing the wire hanging portion blank, specifically, folding the end of the wire hanging portion blank outward to form the above-mentioned wire hanging portion 110;

[0054] Installing the annular varistor 400: embedding the annular varistor 400 in the annular installation groove 300, and welding the annular varistor 400 to the copper shell 120;

[0055] Inner hole withstand voltage test: Conduct withstand voltage test on the commutator structure to confirm whether a short circuit occurs after the wire hanging part 110 is deformed during extrusion molding of the insulating substrate 200;

[0056] Appearance inspection: Check the appearance of the commutator structure for obvious defects;

[0057] Packaging and shipment: The commutator structure that has passed the inner hole pressure resistance inspection and the appearance inspection will be packaged and shipped.

[0058] According to the second aspect of the embodiment of the present invention, a zero-gravity chair motor is also provided, including the commutator structure provided by the first aspect of the embodiment of the present invention. The commutator structure of the zero-gravity chair motor of this embodiment is provided with a boss 220 protruding from the middle of one end of the insulating base 200 away from the hanging wire part 110, and the clamping area between the outer wall of the boss 220 and the inner wall of the commutator body 100 forms an annular mounting groove 300, and the annular mounting groove 300 is provided for the annular varistor 400 to be embedded, and the bottom end of the annular varistor 400 is supported and abutted and supported, and the inner and outer side walls of the annular varistor 400 are limited. It is only necessary to weld the top end surface of the annular varistor 400 away from the hanging wire part 110 in the axial direction to the commutator body 100, that is, only one surface of the annular varistor 400 needs to be welded to meet the fixed connection requirements, and the welding process is simpler and the welding efficiency is improved. Because the annular varistor 400 is welded and fixed in the end of the commutator body 100 away from the hanging part 110, when the carbon brush contacts the outer surface of the commutator body 100 and generates voltage during the operation of the zero-gravity seat motor of this embodiment, the annular varistor 400 is turned on to generate heat and absorb the pulse voltage, thereby ensuring that there will be no commutation sparks to corrode the outer surface of the commutator body 100, so that the outer surface of the commutator body 100 is less worn to ensure the service life, and avoids the generation of strong pulse oscillations and causing large noise, which significantly improves the mechanical properties of the zero-gravity seat motor of this embodiment and meets the high quietness and high stability of the zero-gravity seat operation requirements; at the same time, by embedding the annular varistor 400 in the end face of the commutator body 100 away from the hanging part 110, it can avoid increasing the axial size of the commutator structure of the zero-gravity seat motor of this embodiment, and avoid the annular varistor 400 interfering with the action of winding the rotor winding on the hanging part 110.

[0059] Although the embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art may make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations are all within the scope defined by the present invention.

Claims

1. A commutator structure, applied to a zero-gravity chair motor, characterized in that: The commutator structure comprises: A commutator body (100) is provided with a central hole therein, and a plurality of wire hanging portions (110) are arranged at intervals along the circumferential direction on one end surface of the commutator body (100) along the axial direction; An insulating base (200) is arranged in the central hole and is used to insulate and isolate two adjacent wire hanging parts (110); a central axial hole (210) is arranged in the insulating base (200); a boss (220) is protruded from the middle of the end surface of the insulating base (200) axially away from the wire hanging part (110); an annular mounting groove (300) is formed between the outer wall of the boss (220), the inner wall of the commutator body (100) and the end surface of the insulating base (200) away from the wire hanging part (110); The annular varistor (400) is embedded in the annular mounting groove (300) and welded to the commutator body (100).

2. A commutator structure according to claim 1, characterized in that: The annular varistor (400) is configured as an oxidized zinc-plated resistor.

3. A commutator structure according to claim 1, characterized in that: One end of the wire hanging portion (110) axially away from the commutator body (100) is folded outward to form a hook portion.

4. A commutator structure according to claim 3, characterized in that: The wire hanging portion (110) is arranged in an inverted V shape, one end of the wire hanging portion (110) connected to the commutator body (100) is arranged as a first connecting section (111), and the other end is arranged as a second connecting section (112), and the angle between the arrangement direction of the second connecting section (112) and the axial direction is arranged to be 25° to 35°.

5. A commutator structure according to claim 1, characterized in that: One end of the boss (220) axially away from the wire hanging portion (110) extends to the outside of the central hole.

6. A commutator structure according to claim 1, characterized in that: The commutator body (100) is provided with a copper shell (120), the center hole is formed inside the copper shell (120), and the side wall of the copper shell (120) is provided with an insulating groove (121) corresponding to the clamping area of ​​each adjacent two wire hanging parts (110) along the circumferential direction, and the insulating groove (121) penetrates the copper shell (120) along the axial direction.

7. A commutator structure according to claim 6, characterized in that: The wire hanging portion (110) and the copper shell (120) are integrally stamped and formed.

8. A commutator structure according to claim 6, characterized in that: A hook body (130) is provided at a position where the inner wall of the copper shell (120) and each of the wire hanging parts (110) are located in the same straight line along the axial direction, and the hook body (130) extends along the radial direction of the copper shell (120) toward the center of the copper shell (120); the upper end surface of the hook body (130) along the axial direction is provided as a first inclined surface (131), and the first inclined surface (131) extends from the outside to the inside along the radial direction of the copper shell (120) and is arranged to be inclined upward; the lower end surface of the hook body (130) along the axial direction is provided as a second inclined surface (132), and the second inclined surface (132) extends from the outside to the inside along the radial direction of the copper shell (120) and is arranged to be inclined downward.

9. A commutator structure according to claim 1, characterized in that: The insulating substrate (200) is configured as a bakelite body.

10. A zero gravity chair motor, characterized in that: The commutator structure comprises the commutator structure as claimed in any one of claims 1 to 9.

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