A commutation segment, a commutation segment positioning tooling and a forming method of a commutator

Abstract

A commutator segment is a strip-shaped component, including a body, a neck, and a process handle; the body is inserted into the slot of the rotor lamination, and the process handle is inserted into the positioning tooling. A commutator segment positioning tooling includes a mandrel and a toothed positioning sleeve; a circle of tooth grooves are distributed on the outer circumference of the toothed positioning sleeve, and the number and positions of the tooth grooves correspond to the slots on the rotor stack. The rotor stack and the toothed positioning sleeve are sleeved on the mandrel and form a clearance fit. A forming method of a commutator positions the commutator segment in the rotor stack through the commutator segment positioning tooling and performs subsequent processing techniques. The present invention designs the commutator segment as an independent component, facilitating the processing of the commutator segment. A corresponding positioning tooling is designed for the commutator segment, which can accurately position the commutator segment on the rotor stack, ensuring the accuracy of each spacing dimension and position within the rotor stack, thereby improving the overall precision quality of the commutator.

Description

Technical Field

[0001] The present invention belongs to the field of manufacturing commutators of electric motors, and relates to a commutator segment, a commutator segment positioning tooling and a forming method of a commutator. Background Art

[0002] Commutators are widely used in generators and electric motors and are parts for conducting and converting electric current. The quality and precision of commutators directly affect the performance of electric motors. Therefore, the manufacturing method of commutators is a core link in the processing technology of electric motors. An important link in the manufacturing process of commutators is to insert a commutator segment assembly into a rotor stack. The existing commutator segment assemblies used in DC torque motor commutators have a cylindrical base, and a plurality of commutator segments are vertically arranged on the circumference of the end face of the base. The commutator segments and the base are an integral body. The problems of such commutator segments are as follows: the processing difficulty is large. Because the base and the plurality of commutator segments on the base are an integral body, when processing a single commutator segment, it will be restricted by the positions and spaces of the surrounding commutator segments, resulting in large processing difficulty and easy occurrence of processing errors. In addition, when the existing commutator segment assembly is inserted into the rotor stack, it is positioned manually. Although being limited by the base can ensure that the commutator segments are inserted into the slots of the rotor stack simultaneously and remain basically consistent. However, since windings are wound in the slots of the rotor stack, and the windings will occupy the inside of the slots of the rotor stack, when the commutator segments are inserted into the slots, the commutator segments are prone to shaking under the influence of the windings, and the stability of the installation of the commutator segments cannot be ensured. Furthermore, the internal dimension intervals of the slots of the rotor stack cannot be evenly divided, and installation errors are likely to occur, affecting the precision of the commutator. Summary of the Invention

[0003] In view of this, the present invention provides a commutator segment, a commutator segment positioning tooling and a forming method of a commutator, which reduce the processing difficulty of the commutator segment and enable the commutator segment to be in a uniform and stable state during the process of being inserted into the slots of the rotor stack, thereby improving the production precision of the commutator.

[0004] The technical solution adopted by the present invention is: a commutator segment, characterized in that: it is a strip-shaped component, and the commutator segment includes three sections, which are the front-section body, the middle-section neck and the rear-section process handle in sequence; the body is inserted into the slot of the rotor stack, the end of the body extends out of the upper end of the slot, and the width of the body is smaller than the width of the slot; the width of the neck is greater than the widths of the body and the process handle.

[0005] Further, a groove is provided at the end of the commutator segment for fixing a wire.

[0006] Further, chamfers are provided at the ends of the body and the process handle.

[0007] A commutator segment positioning tooling, characterized in that: it includes a mandrel and a toothed positioning sleeve; a circle of tooth grooves is distributed on the outer circumference of the toothed positioning sleeve, the number of tooth grooves is the same as the number of notches on the rotor laminate, and the corresponding positions of the tooth grooves are the same as the target positions where the commutator segments are inserted into the rotor laminate; the width of the tooth grooves is adapted to the width of the process handle of the commutator segment and can form a clearance fit, and the depth of the tooth grooves is the same as the thickness of the process handle; the rotor laminate and the toothed positioning sleeve are respectively sleeved on the mandrel and respectively form a clearance fit with the mandrel.

[0008] Furthermore, the mandrel includes two separated shafts, namely an upper shaft and a lower shaft. A through shaft hole is provided at the axial center positions of the upper shaft and the lower shaft, and the upper shaft and the lower shaft are connected by a locking shaft passing through the shaft hole.

[0009] Furthermore, the upper shaft and the lower shaft are respectively provided with shaft necks at the relatively connected ends. The shaft diameters of the two shaft necks are the same. Shaft shoulders are provided on the outer sides of the two shaft necks. The rotor laminate is sleeved at the positions of the two shaft necks. The total length of the two shaft necks is less than the thickness of the rotor laminate, and the side surface of the rotor laminate abuts against the two shaft shoulders.

[0010] Furthermore, the locking shaft includes a shaft seat and a cover plate. The shaft seat includes a bottom plate and a shaft body vertically arranged on the bottom plate. The diameter of the bottom plate is larger than the aperture of the shaft hole of the lower shaft. A threaded hole is provided at the axial center position at the top of the shaft body; a through hole is provided at the center of the cover plate. The cover plate is covered on the end face of the upper shaft and the through hole communicates with the shaft hole; the shaft body of the shaft seat penetrates from the lower shaft into the upper shaft, and the cover plate is connected to the threaded hole of the shaft seat through a locking screw.

[0011] A forming method of a commutator, characterized in that:

[0012] Step 1: Sleeve the rotor laminate on the mandrel of the commutator segment positioning tooling;

[0013] Step 2: Insert the body of the commutator segment into the notches of the rotor laminate in Step 1 in sequence;

[0014] Step 3: Sleeve the toothed positioning sleeve of the commutator segment positioning tooling on the mandrel;

[0015] Step 4: Insert the process handle of the commutator segment in Step 2 into the corresponding tooth grooves of the toothed positioning sleeve;

[0016] Step 5: Cast, dry, demold and form the rotor laminate with the commutator segments positioned in Step 4 to obtain a formed commutator.

[0017] The beneficial effects of the present invention are: The commutator segments are designed as independent components, which is convenient for the processing of the commutator segments. A corresponding positioning tooling is designed for the commutator segments, which can accurately position the commutator segments on the rotor laminate, ensure the accuracy of each spacing dimension and position in the rotor laminate, and thus improve the overall precision quality of the commutator. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic structural diagram of a rotor laminate.

[0019] Figure 2 It is a schematic structural diagram of a commutator segment.

[0020] Figure 3 It is an assembly drawing of the commutator segment and the rotor laminate.

[0021] Figure 4 It is a schematic structural diagram of a toothed positioning sleeve.

[0022] Figure 5 It is an assembly schematic diagram of a commutator segment positioning tooling.

[0023] Figure 6 It is a schematic structural diagram of the rotor laminate after forming.

[0024] In the figure: 1. Rotor laminate, 2. Slot opening, 3. Commutator segment, 3-1. Body, 3-2. Neck, 3-3. Process handle, 3-4. Groove, 4. Toothed positioning sleeve, 5. Tooth groove, 6. Mandrel, 6-1. Upper shaft, 6-2. Lower shaft, 6-3. Shaft seat, 6-4. Cover plate, 6-5. Locking screw. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0025] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0026] As Figure 1 shown, multiple straight grooves are distributed on the outer circle of the rotor laminate 1, and the cross-section of each groove is V-shaped. The commutator segment 3 is inserted at the position of the slot opening 2 of the V-shaped groove.

[0027] As Figure 2As shown, the commutator segment 3 is a strip-shaped component. The commutator segment 3 includes three sections, namely the front-section body 3-1, the middle-section neck 3-2, and the rear-section process handle 3-3 in sequence. The body 3-1 is used to be inserted into the slot 2 of the rotor lamination. The width of the body 3-1 is smaller than the width of the slot 2, and there are gaps between both sides of the body 3-1 and both sides of the slot 2. The end of the body 3-1 is inserted from the lower end of the slot 2 and passes through from the upper end. The function of the neck 3-2 is that after the commutator segment 3 and the rotor stack 1 are positioned by the positioning tooling, a distance needs to be left between the rotor stack 1 and the positioning tooling to facilitate the subsequent processing technology. Therefore, the width of the neck 3-2 needs to be greater than the widths of the body 3-1 and the process handle 3-3. At the same time, the width of the neck 3-2 is greater than the widths of the slot 2 of the rotor stack 1 and the tooth grooves 5 for positioning of the positioning tooling, so that the upper end of the neck 3-2 abuts against both sides of the lower end of the slot 2, and the lower end abuts against both sides of the upper end of the tooth groove 5. It should be noted that since the interval between adjacent commutator segments 3 is small, in order not to affect the installation of adjacent commutator segments 3, it is required that the position where the neck 3-2 abuts against the slot 2 does not exceed the midline of two adjacent slots 2, and the position where the neck 3-2 abuts against the tooth groove 5 does not exceed the midline of two adjacent tooth grooves 5.

[0028] Since windings will be provided in the rotor stack 1 and the ends of the winding wires need to be fixed, a groove 3-4 is provided at the end of the commutator segment 3 extending out of the slot 2 to fix the wires. In order to facilitate the positioning and insertion of the commutator segment 3, chamfers are provided at the ends of the body 3-1 and the process handle 3-3.

[0029] As Figure 5 shown, a commutator segment 3 positioning tooling includes a mandrel 6 and a toothed positioning sleeve 4. As Figure 4 shown, a circle of tooth grooves 5 are distributed on the outer circumference of the toothed positioning sleeve 4. The number of the tooth grooves 5 is the same as the number of the slots 2 on the rotor stack 1, and they are also straight grooves. The positions where the tooth grooves 5 are located are the same as the target positions where the commutator segments 3 are inserted into the slots 2 of the rotor stack 1. The width of the tooth groove 5 is adapted to the width of the process handle 3-3 of the commutator segment 3 for clearance fit. The depth of the tooth groove 5 is the same as the thickness of the process handle 3-3. That is to say, the handle body of the process handle 3-3 and the bottom of the tooth groove 5 are in a fitting state to ensure the stability of positioning.

[0030] As Figure 5 shown, the mandrel 6 is used to stabilize the rotor stack 1 and the toothed positioning sleeve 4. The rotor stack 1 and the toothed positioning sleeve 4 are respectively sleeved on the shaft body of the mandrel 6, and corresponding shaft diameters are set on the mandrel 6 to form clearance fits respectively.

[0031] Since the mandrel 6 is used to stabilize the rotor stack 1 and the tooth-shaped positioning sleeve 4, it needs to have a limiting structure. Also, since the rotor stack 1 is not fully formed and fixed when the commutator segments 3 are inserted, when the rotor stack 1 is sleeved on the mandrel 6, the mandrel 6 needs to provide a locking function for it to ensure that the rotor laminations on the rotor stack 1 do not rotate and misalign. The mandrel 6 includes two separated shafts, namely the upper shaft 6-1 and the lower shaft 6-2. A through shaft hole is provided at the axial center position of the upper shaft 6-1 and the lower shaft 6-2. The upper shaft 6-1 and the lower shaft 6-2 are connected by a locking shaft passing through the shaft hole. At the relatively connected ends of the upper shaft 6-1 and the lower shaft 6-2, there are respectively provided shaft necks, and the shaft diameters of the two shaft necks are the same. On the outer sides of the two shaft necks, there are respectively provided shaft shoulders. The total length of the two shaft necks is less than the thickness of the rotor stack 1. During installation, the rotor stack 1 is first sleeved on the shaft neck of the lower shaft 6-2, then the shaft neck of the upper shaft 6-1 is sleeved inside the rotor stack 1, and then it is locked by the locking shaft. During the locking process, the two shaft shoulders will squeeze the side surface of the rotor stack 1 to achieve the locking function.

[0032] As Figure 5 shown, the locking shaft includes a shaft seat 6-3 and a cover plate 6-4. The bottom of the shaft seat 6-3 is provided with a bottom plate, and a shaft body is vertically provided on the bottom plate. The diameter of the bottom plate is larger than the aperture of the shaft hole of the lower shaft 6-2. A threaded hole is provided at the axial center position at the top of the shaft body. A through hole is provided at the center of the cover plate 6-4 for covering the end face of the upper shaft 6-1, and the through hole of the cover plate 6-4 communicates with the shaft hole of the upper shaft 6-1. The shaft body of the shaft seat 6-3 passes through the lower shaft 6-2 and into the upper shaft 6-1. After covering the cover plate 6-4 at the end of the upper shaft 6-1, it is connected to the threaded hole at the top of the shaft seat 6-3 by a locking screw 6-5. The length of the threaded hole is greater than the length of the screw.

[0033] A forming method for a commutator is as follows:

[0034] Step 1: Sleeve the rotor stack on the mandrel of the commutator segment positioning tooling;

[0035] Step 2: Insert the body of the commutator segment into the slot openings of the rotor stack in Step 1 in sequence;

[0036] Step 3: Sleeve the tooth-shaped positioning sleeve of the commutator segment positioning tooling on the mandrel;

[0037] Step 4: Insert the process handle of the commutator segment in Step 2 into the corresponding tooth grooves of the tooth-shaped positioning sleeve;

[0038] Step 5: Cast, dry, demold and form the rotor stack with the commutator segments positioned in Step 4 to obtain a formed commutator.

Claims

1. A commutator segment positioning tooling, characterized in that: It includes a mandrel and a toothed positioning sleeve; a circle of tooth grooves are distributed on the outer circumference of the toothed positioning sleeve, the number of tooth grooves is the same as the number of notches on the rotor stack, and the corresponding positions of the tooth grooves are the same as the target positions where the commutator segments are inserted into the rotor stack; the width of the tooth grooves is adapted to the width of the process handle of the commutator segment and can be in clearance fit, and the depth of the tooth grooves is the same as the thickness of the process handle; the rotor stack and the toothed positioning sleeve are respectively sleeved on the mandrel and form clearance fits with the mandrel respectively; the mandrel includes two separated shafts, namely an upper shaft and a lower shaft, through holes are provided at the axial center positions of the upper shaft and the lower shaft, and the upper shaft and the lower shaft are connected by a locking shaft passing through the through hole.

2. The commutator segment positioning tooling according to claim 1, characterized in that: The upper shaft and the lower shaft are respectively provided with shaft necks at the relatively connected ends, the shaft diameters of the two shaft necks are the same, shoulders are provided on the outer sides of the two shaft necks, the rotor stack is sleeved at the positions of the two shaft necks, the total length of the two shaft necks is less than the thickness of the rotor stack, and the side surface of the rotor stack abuts against the two shoulders.

3. The commutator segment positioning tooling according to claim 1, characterized in that: The locking shaft includes a shaft seat and a cover plate. The shaft seat includes a bottom plate and a shaft body vertically arranged on the bottom plate. The diameter of the bottom plate is larger than the aperture of the shaft hole of the lower shaft, and a threaded hole is provided at the axial center position at the top of the shaft body; a through hole is provided at the center of the cover plate, the cover plate is installed on the end surface of the upper shaft and the through hole communicates with the shaft hole; the shaft body of the shaft seat penetrates from the lower shaft to the upper shaft, and the cover plate is connected to the threaded hole of the shaft seat by a locking screw.

4. The commutator segment positioning tooling according to claim 1, characterized in that: The commutator segment is a strip-shaped component, and the commutator segment includes three sections, namely a front section of the body, a middle section of the neck and a rear section of the process handle in sequence; the body is inserted into the notch of the rotor lamination, the end of the body extends out of the upper end of the notch, and the width of the body is less than the width of the notch; the width of the neck is greater than the widths of the body and the process handle.

5. The commutator segment positioning tooling according to claim 4, characterized in that: A groove is provided at the end of the commutator segment for fixing a wire.

6. The commutator segment positioning tooling according to claim 4, characterized in that: Chamfers are provided at the ends of the body and the process handle.

7. A forming method of a commutator, characterized in that: Step 1: Sleeve the rotor stack on the mandrel of the commutator segment positioning tooling. Step 2: Insert the body of the commutator segment into the notches of the rotor stack in Step 1 in sequence. Step 3: Sleeve the toothed positioning sleeve of the commutator segment positioning tooling on the mandrel. Step 4: Insert the process handle of the commutator segment in Step 2 into the corresponding tooth grooves of the toothed positioning sleeve. Step 5: Cast, dry, demold and form the rotor stack with the commutator segment positioned in Step 4 to obtain a formed commutator.

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