Pure copper mica-free commutator and its production process

Abstract

The present invention relates to the technical field of commutators, and more specifically, discloses a pure copper mica-free commutator and a production process thereof, comprising a commutator body, the commutator body comprising commutator segments, the commutator segments comprising a commutator segment body and a root portion; two first positioning blocks are provided on both end faces of the commutator segment body along the short axis direction, the two first positioning blocks are spaced apart along the length direction of the commutator segment body, a second positioning block is provided between the two first positioning blocks, the first positioning block and the second positioning block on the same end face of the commutator segment body are staggered along the short axis direction of the commutator segment body, the first positioning blocks on the two end faces of the commutator segment body are staggered along the short axis direction of the commutator segment body, and correspondingly, the second positioning blocks on the two end faces of the commutator segment body are staggered. The present invention not only improves the segment arrangement efficiency during the commutator production process, but also avoids interference with subsequent production processes caused by misalignment between two adjacent commutator segments.

Description

Technical Field

[0001] The present invention relates to the technical field of commutators, in particular to a pure copper mica-free commutator and a production process thereof. Background Art

[0002] The commutator is a crucial component in DC motors. Currently, during commutator manufacturing, mica sheets and commutator segments are arranged alternately to prevent adjacent segments from contacting and causing short circuits. However, arranging the mica sheets and commutator segments is complex and requires high precision. Misalignment of the mica sheets can cause commutator processing to fail, increasing both the difficulty and labor costs.

[0003] Patent document CN201320376052.X discloses a mica-free commutator structure comprising a base and commutator segments, the commutator segments being arranged circumferentially along the base. The commutator segments comprise a commutator body and a root portion. The structure is characterized in that the commutator body is provided with positioning blocks on both sides along the minor axis, the thickness of the positioning blocks being less than that of the commutator body. Although this utility model reduces processing difficulty and improves production efficiency, the positioning blocks are fixed in position during commutator segment arrangement, which can lead to misalignment between the positioning blocks on adjacent commutator segments, thus hindering efficient segment arrangement. Summary of the Invention

[0004] To address the existing drawback of conventional mica-free commutators, which can cause misalignment between adjacent commutator segments during segment arrangement, the present invention provides a pure copper mica-free commutator and its production process. This prevents misalignment between adjacent commutator segments during segment arrangement.

[0005] In order to solve the above technical problems, the present invention is solved by the following technical solutions:

[0006] A pure copper mica-free commutator comprises a commutator body, the commutator body comprises a base, commutator segments are arranged on the base along the circumferential direction, adjacent commutators are insulated by gaps, and the commutator segments comprise a commutator segment body and a root; two first positioning blocks are respectively provided on both end surfaces of the commutator segment body along the short axis direction, the thickness of the first positioning blocks is half the thickness of the commutator segment body, the two first positioning blocks are spaced apart along the length direction of the commutator segment body, a second positioning block is provided between the two first positioning blocks, the thickness of the second positioning block is half the thickness of the commutator segment body, the first positioning block and the second positioning block on the same end surface of the commutator segment body are staggered along the short axis direction of the commutator segment body, the first positioning blocks on both end surfaces of the commutator segment body are staggered along the short axis direction of the commutator segment body, and correspondingly, the second positioning blocks on both end surfaces of the commutator segment body are staggered.

[0007] The provision of the first and second positioning blocks of the present invention effectively prevents misalignment between adjacent commutator segments during the segment arrangement process, thereby preventing interference with the pressing process. This improves segment arrangement efficiency during commutator production and prevents interference with subsequent production processes caused by misalignment between adjacent commutator segments.

[0008] Preferably, grooves are provided at both ends of the upper end portion of the commutator segment body along the short axis direction.

[0009] In the present invention, by providing the groove, when milling the commutator, the groove can be carved at the groove, thereby facilitating the milling of the groove.

[0010] The present invention also provides a commutator production process for producing the pure copper mica-free commutator, which comprises the following steps:

[0011] Step 1: The copper material is sequentially extruded, stretched, punched and sheared, and vibrated to obtain a commutator segment;

[0012] Step 2: Beat the bakelite powder into cakes;

[0013] Step 3: Pressing the commutator segments and bakelite powder obtained in Step 1 and Step 2 into a shape and curing them to obtain a primary commutator product;

[0014] Step 4: The commutator is made into a primary product in step 3 and is bored, turned into an outer circle, bored into an inner hole of a hook foot, milled into a groove, milled into a hook foot, returned to the hole, squeezed into the hook foot and bent into a commutator body;

[0015] Step 5: Test the commutator body manufactured in step 4.

[0016] The production process of the pure copper mica-free commutator in the present invention does not require the use of mica sheets when arranging the commutator segments, thereby effectively improving the segment arrangement efficiency, simplifying the production process of the commutator, and avoiding the use of mica sheets, thereby reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a top view of the pure copper mica-free commutator in Example 1.

[0018] Figure 2 This is a cross-sectional view of the pure copper mica-free commutator in Example 1.

[0019] Figure 3 for Figure 2 Schematic diagram of the structure of the commutator segment.

[0020] The parts indicated by the numbers in the accompanying drawings are as follows:

[0021] 100, commutator body; 110, base; 120, commutator segment; 310, commutator segment body; 311, first positioning block; 312, second positioning block; 320, root; 330, groove. DETAILED DESCRIPTION

[0022] In order to further understand the content of the present invention, the present invention is described in detail with reference to the accompanying drawings and embodiments. It should be understood that the embodiments are merely for explaining the present invention and are not intended to limit the present invention. Example

[0023] like Figure 1-3 As shown, this embodiment provides a pure copper mica-free commutator, which includes a commutator body 100, the commutator body includes a base 110, and commutator segments 120 are arranged on the base 110 along the circumferential direction. Adjacent commutators are insulated by gaps. The commutator segments 120 include a commutator segment body 310 and a root 320; two first positioning blocks 311 are provided on both end surfaces of the commutator segment body 310 along the short axis direction. The thickness of the first positioning blocks 311 is half the thickness of the commutator segment body 310. The two first positioning blocks 311 are arranged along the commutator segment body 310. 0 length direction, a second positioning block 312 is provided between the two first positioning blocks 311, and the thickness of the second positioning block 312 is half of the thickness of the commutator segment body 310. The first positioning block 311 and the second positioning block 312 on the same end face of the commutator segment body 310 are staggered along the short axis direction of the commutator segment body 310. The first positioning blocks 311 on both end faces of the commutator segment body 310 are staggered along the short axis direction of the commutator segment body 310. Correspondingly, the second positioning blocks 312 on both end faces of the commutator segment body 310 are staggered.

[0024] By providing the first positioning block 311 and the second positioning block 312 in this embodiment, when commutator segments 120 need to be arranged during commutator production, several commutator segments 120 can be arranged in sequence so that the second positioning blocks 312 on two adjacent commutator segments extend between the two first positioning blocks 311. Compared to the mica-free commutator structure in the prior art, this more effectively avoids misalignment between two adjacent commutator segments 120 during the commutation process, which could interfere with the pressing process. This improves the commutator production process's commutation efficiency and avoids interference with subsequent production processes caused by misalignment between two adjacent commutator segments 120.

[0025] In this embodiment, grooves 330 are provided at both ends of the upper end portion of the commutator segment body 310 along the short axis direction.

[0026] By providing the groove 330 in this embodiment, when milling the commutator, the groove can be cut at the groove 330 , thereby facilitating the milling of the groove.

[0027] This embodiment also provides a production method for producing the pure copper mica-free commutator, which comprises the following steps:

[0028] Step 1: The copper material is sequentially extruded, stretched, punched and sheared, and vibrated to obtain the commutator segment 120;

[0029] Step 2: Beat the bakelite powder into cakes;

[0030] Step 3: Pressing the commutator segments 120 and bakelite powder obtained in Steps 1 and 2 into a shape and curing them to obtain a primary commutator product;

[0031] Step 4: The commutator product made in step 3 is subjected to boring, turning of the outer circle, boring of the inner hole of the hook foot, milling of the groove, milling of the hook foot, re-boring, extrusion of the hook foot and bending of the hook to form the commutator body 100;

[0032] Step 5: inspect the commutator body 100 manufactured in step 4.

[0033] The pure copper mica-free commutator production process in this embodiment overcomes the problem of the need to insert mica sheets during the sheet arrangement process in the conventional insert-type commutator manufacturing method. When arranging the commutator segments 120, no mica sheets are required, thereby effectively improving the sheet arrangement efficiency, simplifying the production process of the commutator, and avoiding the use of mica sheets, thereby reducing production costs.

[0034] In short, the above description is only a preferred embodiment of the present invention, and all equivalent changes and modifications made according to the scope of the patent application of the present invention should fall within the scope of the patent of the present invention.

Claims

1. Pure copper mica-free commutator, characterized by: The invention comprises a commutator body (100), the commutator body comprises a base (110), a commutator segment (120) is arranged on the base (110) along the circumferential direction, adjacent commutators are insulated by gaps, and the commutator segment (120) comprises a commutator segment body (310) and a root (320); two first positioning blocks (311) are provided on both end surfaces of the commutator segment body (310) along the short axis direction, the thickness of the first positioning blocks (311) is half the thickness of the commutator segment body (310), and the two first positioning blocks (311) are spaced apart along the length direction of the commutator segment body (310). A second positioning block (312) is provided between the first positioning blocks (311). The thickness of the second positioning block (312) is half the thickness of the commutator segment body (310). The first positioning block (311) and the second positioning block (312) on the same end face of the commutator segment body (310) are staggered along the short axis direction of the commutator segment body (310). The first positioning blocks (311) on both end faces of the commutator segment body (310) are staggered along the short axis direction of the commutator segment body (310). Correspondingly, the second positioning blocks (312) on both end faces of the commutator segment body (310) are staggered.

2. The pure copper mica-free commutator according to claim 1, characterized in that: Grooves (330) are provided at both ends of the upper end portion of the commutator segment body (310) along the minor axis direction.

3. A process for producing the pure copper mica-free commutator according to claim 1, comprising the following steps: Step 1: sequentially extruding, stretching, punching and shearing the copper material, and vibrating and cleaning the copper material to obtain a commutator segment (120); Step 2: Beat the bakelite powder into cakes; Step 3: pressing the commutator segments (120) and bakelite powder obtained in Step 1 and Step 2 into a shape, and curing the shapes to obtain a primary commutator product; Step 4: The commutator is initially manufactured in step 3 and is subjected to boring, turning of the outer circle, boring of the inner hole of the hook foot, milling of the groove, milling of the hook foot, re-boring, squeezing of the hook foot and bending of the hook to manufacture the commutator body (100); Step 5: inspect the commutator body (100) manufactured in step 4.

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