Commutator, motor, and method for manufacturing commutator

Abstract

The present invention relates to the field of motor technology, and provides a commutator, a motor, and a method for manufacturing a commutator. The commutator includes: a plurality of commutator segments, which are arranged in a cylindrical structure at intervals along the circumferential direction, and each pair of commutator segments is composed of two commutator segments symmetrically distributed relative to the axis of the cylindrical structure; a plurality of wires, which are arranged in the cylindrical structure, and each of the wires electrically connects two of the commutator segments in a pair of the commutator segments; and an annular insulator, which is filled in the cylindrical structure, and the annular insulator isolates and supports the plurality of commutator segments and the plurality of wires. The present invention forms a stable commutator structure by embedding the wires used for voltage balancing into the commutator, and isolating and supporting the commutator segments and the wires through the insulator; while achieving the voltage balancing effect, it reduces the difficulty of winding, avoids the hook of the commutator segment from being welded due to the connection of too many wires, and at the same time avoids affecting the insulation performance of the armature neck, thereby ensuring the stability of the motor.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a commutator, a motor and a method for manufacturing the commutator. Background Art

[0002] In a car's electronic power steering (EPS), the motor is a crucial component that powers the EPS. Brushed motors are widely used in EPS due to their low cost and fast startup.

[0003] During operation, brushed motors are prone to noise problems due to unbalanced current.

[0004] At present, the way to solve the noise problem of brushed motors is to use a voltage-equalizing wire, bypass the winding slots of the armature, and connect the corresponding commutator segments, so that the commutator segments at the same potential are electrically connected to improve the noise.

[0005] However, the current method requires an additional armature winding process, which increases the difficulty of the process; moreover, the hook of a commutator segment itself needs to be welded with two winding lead wires, and the design of the equalizing wire requires an additional wire to be welded to the hook of the commutator segment, which reduces the welding strength and welding quality; in addition, the equalizing wire is wrapped around the armature neck, affecting the insulation performance of the armature.

[0006] It should be noted that the information disclosed in the above background technology section is only used to enhance the understanding of the background of the present invention, and therefore may include information that does not constitute prior art known to ordinary technicians in this field. Summary of the Invention

[0007] In view of this, the present invention provides a commutator, a motor and a method for manufacturing a commutator, wherein a wire for voltage equalization is built into the commutator, and the commutator segments and the wire are isolated and supported by an insulator, thereby forming a stable commutator structure; while achieving the voltage equalization effect, the winding difficulty is reduced, and the hook portion of the commutator segment is prevented from welding due to connecting too many wires, thereby avoiding affecting the insulation performance of the armature neck, thereby ensuring the stability of the motor.

[0008] One aspect of the present invention provides a commutator, comprising: a plurality of commutator segments arranged at intervals along the circumferential direction to form a cylindrical structure, wherein two commutator segments symmetrically distributed relative to the axis of the cylindrical structure constitute a pair of commutator segments; a plurality of wires arranged in the cylindrical structure, wherein each wire electrically connects two commutator segments in a pair of the commutator segments; and an annular insulator filled in the cylindrical structure, wherein the annular insulator isolates and supports the plurality of commutator segments and the plurality of wires.

[0009] In some embodiments, the two commutator segments in a pair of the commutator segments are 180° apart in the circumferential direction; each of the wires extends from the top inner wall of the first commutator segment in the pair of the commutator segments to the bottom inner wall of the second commutator segment in the pair of the commutator segments.

[0010] In some embodiments, each of the conductive wires avoids the axial hole of the annular insulator and extends in the same clockwise direction within the cylindrical structure.

[0011] In some embodiments, the plurality of wires electrically connecting the plurality of pairs of commutator segments arranged along the clockwise direction are sequentially stacked in the axial direction of the cylindrical structure and spaced apart from each other.

[0012] In some embodiments, the conductive wire is formed into a flat shape in which a width along the circumferential direction is greater than a thickness along the axial direction of the cylindrical structure.

[0013] In some embodiments, the spacing between adjacent commutator segments along the circumferential direction is equal; the outer walls of the plurality of commutator segments and the portion of the annular insulator filled between the plurality of commutator segments together form the cylindrical outer wall of the commutator.

[0014] In some embodiments, the material of the annular insulator is phenolic resin.

[0015] Another aspect of the present invention provides a method for manufacturing a commutator, which is used to manufacture the commutator described in any of the above embodiments, the manufacturing method comprising: arranging a plurality of commutator segments at intervals along the circumferential direction, so that the plurality of commutator segments are arranged into a cylindrical structure, and each two commutator segments symmetrically distributed relative to the axis of the cylindrical structure constitute a pair of commutator segments; laying a plurality of wires in the cylindrical structure, so that each of the wires electrically connects two of the commutator segments in a pair of the commutator segments; and filling the cylindrical structure with an annular insulator, so that the annular insulator isolates and supports the plurality of commutator segments and the plurality of wires.

[0016] In some embodiments, the wire is electrically connected to the commutator segment by welding; and the annular insulator is formed by an injection molding process.

[0017] Another aspect of the present invention provides a motor, comprising: an armature, comprising an iron core fixed to a rotating shaft and a plurality of winding elements wound around the iron core; a commutator described in any of the above embodiments, wherein the commutator is fixed to the rotating shaft through the axial hole of the annular insulator, and the lead wires of each of the winding elements are electrically connected to the hook portion of the corresponding commutator segment of the commutator.

[0018] The beneficial effects of the present invention compared with the prior art include at least:

[0019] By embedding the wires used for voltage balancing within the commutator and isolating and supporting the commutator segments and wires with insulators, a stable commutator structure is formed. This reduces the difficulty of winding while achieving voltage balancing, avoids welding aging of the commutator segment hooks due to connecting too many wires, and avoids affecting the insulation performance of the armature neck, thereby ensuring motor stability.

[0020] It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings are incorporated into and constitute a part of this specification, illustrate embodiments consistent with the present invention, and together with the description, serve to explain the principles of the present invention. Obviously, the drawings described below are only some embodiments of the present invention, and it is clear that those skilled in the art can derive other drawings based on these drawings without inventive effort.

[0022] Figure 1 A schematic diagram showing the connection structure of the commutator segments and the wires in an embodiment of the present invention is shown;

[0023] Figure 2 A schematic structural diagram of a commutator according to an embodiment of the present invention is shown;

[0024] Figure 3 A schematic diagram showing the connection of wires of a pair of commutator segments according to an embodiment of the present invention is shown;

[0025] Figure 4 A schematic diagram showing the steps of a method for manufacturing a commutator in an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0026] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to make this disclosure thorough and complete and to fully convey the concepts of the example embodiments to those skilled in the art.

[0027] The accompanying drawings are only schematic illustrations of the present invention and are not necessarily drawn to scale. The same reference numerals in the figures represent the same or similar parts, and their repeated description will be omitted. The terms "first", "second" and similar terms used in the specific description do not indicate any order, quantity or importance, but are only used to distinguish different components. It should be noted that, unless there is a conflict, the embodiments of the present invention and the features of different embodiments can be combined with each other.

[0028] In addition, the processes shown in the drawings are merely exemplary and do not necessarily include all steps. For example, some steps may be decomposed, some steps may be combined or partially combined, and the actual execution order may change according to actual circumstances.

[0029] Figure 1 The connection structure between the commutator segments and the conductors in the embodiment is shown. Figure 2 The structure of the commutator in the embodiment is shown, combined with Figure 1 and Figure 2 As shown, the commutator in this embodiment includes: a plurality of commutator segments 1 arranged circumferentially in a cylindrical structure, with each pair of commutator segments consisting of two commutator segments symmetrically arranged about the axis of the cylindrical structure. The circumferential spacing between adjacent commutator segments 1 is equal; the two commutator segments in a pair are 180° apart in the circumferential direction. Figure 1 11 pairs of commutator segments are shown, namely: commutator segment pair 1-a and 1-a', commutator segment pair 1-b and 1-b'... commutator segment pair 1-k and 1-k'. Of course, the number of commutator segments 1 can be adjusted according to the configuration of the motor.

[0030] Multiple wires 2 are arranged in the cylindrical structure, and each wire 2 electrically connects two commutator segments in a pair of commutator segments. For example, Figure 1 As shown in the figure: the wire 2-a electrically connects the commutator segment pair 1-a and 1-a', the wire 2-b electrically connects the commutator segment pair 1-b and 1-b'... the wire 2-k electrically connects the commutator segment pair 1-k and 1-k'.

[0031] An annular insulator 3 is filled in the cylindrical structure, isolating and supporting multiple commutator segments 1 and multiple wires 2. The annular insulator 3 secures the wires 2 within the cylindrical space enclosed by the commutator segments 1. The axial hole 30 of the annular insulator 3 is used to assemble the commutator to the motor shaft.

[0032] The commutator may also include other conventional structures. For example, a hook portion for connecting to an armature winding is provided at the end of the commutator segment 1 , which is not specifically shown in the figure.

[0033] The above-mentioned commutator forms a stable commutator structure by embedding the wire 2 used for voltage equalization into the commutator and isolating and supporting the commutator segments 1 and the wire 2 through the annular insulator 3; thereby, while achieving the voltage equalization effect, the difficulty of winding is reduced, and the hook of the commutator segment 1 is prevented from being welded due to connecting too many wires, while also avoiding affecting the insulation performance of the armature neck, thereby ensuring the stability of the motor.

[0034] Figure 3 The embodiment shows the wire connection method between a pair of commutator segments, for example, the wire connection method between the commutator segment pair 1-k and 1-k', combined with Figure 1 and Figure 3As shown, wire 2-k extends from the top inner wall of the first commutator segment 1-k in the commutator segment pairs 1-k and 1-k' to the bottom inner wall of the second commutator segment 1-k' in the commutator segment pairs 1-k and 1-k'. By connecting wire 2 from the top of one commutator segment 1 to the bottom of another commutator segment 1, multiple wires 2 can be easily routed within the cylindrical space surrounded by the commutator segments 1, avoiding mutual interference.

[0035] The conductor 2 may be in a flat shape with a width in the circumferential direction greater than a thickness in the axial direction of the cylindrical structure, so as to facilitate welding between the conductor 2 and the commutator segment 1 , and have a certain degree of flexibility to meet wiring requirements.

[0036] Combine Figure 1 and Figure 2 As shown, each wire 2 avoids the axial hole 30 of the annular insulator 3 in the cylindrical structure and extends in the same clockwise direction. For example, referring to the wire 2-k shown in Figure 1, after extending a distance from the first commutator segment 1-k, it extends roughly in the clockwise direction R within the cylindrical structure to bypass the axial hole 30 of the annular insulator 3 and connect to the second commutator segment 1-k'. The wire 2-k extends smoothly as a whole, avoiding large-angle bends and flipping to ensure its wire performance. By having multiple wires 2 extend in the same clockwise direction, it is also easier to organize the wires 2 and avoid interference caused by messy wiring.

[0037] Furthermore, the plurality of wires electrically connecting the plurality of pairs of commutator segments arranged in the clockwise direction are sequentially stacked and spaced apart from each other in the axial direction of the cylindrical structure. Figure 1 As shown, the commutator segment pairs 1-a and 1-a' to the commutator segment pairs 1-k and 1-k' are arranged in sequence along the clockwise direction, and the wires 2-a to 2-k electrically connecting the commutator segment pairs 1-a and 1-a' to the commutator segment pairs 1-k and 1-k' are stacked in sequence from bottom to top in the axial direction and spaced apart from each other, so that the wiring between the multiple wires 2 is orderly and does not interfere with each other.

[0038] Of course, except for the end portion of each wire 2 which is in welding contact with the commutator segment 1 , the rest of the surface is covered with an insulating film, so even if the wires 2 come into contact with each other, there will be no risk.

[0039] The wires 2 are then secured within the cylindrical space enclosed by the commutator segments 1 by an annular insulator 3. The annular insulator, specifically made of phenolic resin, insulates the segments 1 and wires 2 while also supporting them and forming a stable commutator structure. The outer walls of the segments 1 and the interspaces between the segments 1 formed by the annular insulator 3 form the cylindrical outer wall of the commutator, ensuring smooth contact between the commutator and brushes.

[0040] An embodiment of the present invention also provides a motor, comprising: an armature, comprising an iron core fixed to a rotating shaft and a plurality of winding elements wound around the iron core; a commutator described in any of the above embodiments, wherein the commutator is fixed to the rotating shaft through the axial hole of an annular insulator, and the lead wires of each winding element are respectively electrically connected to the hook portion of the corresponding commutator segment of the commutator.

[0041] The winding elements are specifically wound around the teeth slots of the iron core. The wiring method of the winding elements and the connection method between the winding elements and the commutator segments can all adopt existing technologies, so they are not described in detail.

[0042] The motor also includes a stator, which is equipped with fixed main magnetic poles and brushes. The commutator segments are in sliding contact with the brushes. When the motor is running, the DC power supply enters the armature winding through the brushes and commutator, generating armature current. The magnetic field generated by the armature current interacts with the main magnetic field to produce electromagnetic torque, which rotates the motor and drives the load.

[0043] The present invention mainly integrates the wires used for voltage balancing into the commutator, and isolates and supports the commutator segments and the wires through an annular insulator to form a stable commutator structure; thereby, while achieving the voltage balancing effect, the difficulty of winding is reduced, and the hook portion of the commutator segment is prevented from being welded due to the connection of too many wires, while also avoiding affecting the insulation performance of the armature neck, thereby ensuring the stability of the motor.

[0044] Embodiments of the present invention also provide a method for manufacturing a commutator, which can be used to manufacture the commutator described in any of the above embodiments. The features and principles of the commutator described in any of the above embodiments can be applied to the following manufacturing method embodiments. In the following manufacturing method embodiments, the features and principles of the commutator that have already been explained will not be repeated.

[0045] Figure 4 The main steps of the method for manufacturing the commutator in the embodiment are shown, referring to Figure 4 As shown, the manufacturing method in this embodiment includes: step S410, arranging a plurality of commutator segments at intervals along the circumferential direction, so that the plurality of commutator segments are arranged into a cylindrical structure, and each two commutator segments symmetrically distributed relative to the axis of the cylindrical structure constitute a pair of commutator segments; step S420, laying a plurality of wires in the cylindrical structure, so that each wire is electrically connected to two commutator segments in a pair of commutator segments; and step S430, filling the cylindrical structure with an annular insulator, so that the annular insulator isolates and supports the plurality of commutator segments and the plurality of wires.

[0046] The wires and the commutator segments are electrically connected by welding, and the annular insulator is formed by an injection molding process.

[0047] Furthermore, the manufacturing method of the commutator may also include other conventional steps, such as forming hooks at the ends of the commutator segments for welding lead wires of the winding elements, which will not be repeated here.

[0048] The commutator manufactured by the above-mentioned manufacturing method forms a stable commutator structure by embedding the wires used for voltage equalization into the commutator and isolating and supporting the commutator segments and the wires through an annular insulator. Thus, while achieving the voltage equalization effect, the winding difficulty is reduced and the manufacturing process is simplified. The hook portion of the commutator segment is prevented from being welded due to the connection of too many wires, and the insulation performance of the armature neck is not affected, thereby ensuring the stability of the motor.

[0049] The above is a further detailed description of the present invention in conjunction with specific preferred embodiments, and the specific implementation of the present invention should not be considered to be limited to these descriptions. For those skilled in the art of the present invention, without departing from the concept of the present invention, several simple deductions or substitutions can be made, which should be considered to fall within the scope of protection of the present invention.

Claims

1. A commutator, characterized in that: include: A plurality of commutator segments are arranged in a cylindrical structure at intervals along the circumferential direction, wherein two commutator segments symmetrically distributed relative to the axis of the cylindrical structure form a pair of commutator segments, and the two commutator segments in a pair of commutator segments are 180 degrees apart in the circumferential direction; a plurality of wires arranged in the cylindrical structure, each of the wires electrically connecting two commutator segments in a pair of the commutator segments, and each of the wires extending from a top inner wall of a first commutator segment in a pair of the commutator segments to a bottom inner wall of a second commutator segment in the pair of the commutator segments; as well as An annular insulator is filled in the cylindrical structure, and the annular insulator isolates and supports the plurality of commutator segments and the plurality of wires.

2. The commutator according to claim 1, wherein: Each of the conductive wires avoids the axial hole of the annular insulator in the cylindrical structure and extends along the same clockwise direction.

3. The commutator according to claim 2, wherein: The plurality of wires electrically connecting the plurality of pairs of commutator segments arranged in the clockwise direction are sequentially stacked in the axial direction of the cylindrical structure and spaced apart from each other.

4. The commutator according to claim 1, wherein: The conductive wire is formed into a flat shape in which a width in the circumferential direction is greater than a thickness in an axial direction of the cylindrical structure.

5. The commutator according to claim 1, wherein: The spacing between adjacent commutator segments along the circumferential direction is equal; The outer walls of the plurality of commutator segments and the portion of the annular insulator filled between the plurality of commutator segments together form the cylindrical outer wall of the commutator.

6. The commutator according to claim 1, wherein: The material of the annular insulator is phenolic resin.

7. A method for manufacturing a commutator, for manufacturing the commutator according to any one of claims 1 to 6, characterized in that: The production method comprises: A plurality of commutator segments are arranged at intervals along a circumferential direction so as to form a cylindrical structure, wherein two commutator segments symmetrically distributed relative to an axis of the cylindrical structure form a pair of commutator segments, and the two commutator segments in a pair of commutator segments are 180° apart in the circumferential direction; Arranging a plurality of wires in the cylindrical structure, such that each wire electrically connects two commutator segments in a pair of commutator segments, and each wire extends from a top inner wall of a first commutator segment in a pair of commutator segments to a bottom inner wall of a second commutator segment in the pair of commutator segments; and An annular insulator is filled in the cylindrical structure, so that the annular insulator isolates and supports the plurality of commutator segments and the plurality of wires.

8. The production method according to claim 7, characterized in that: The wire is electrically connected to the commutator segment by welding; The annular insulator is formed by an injection molding process.

9. A motor, characterized in that: include: The armature comprises an iron core fixed to the rotating shaft and a plurality of winding elements wound around the iron core; The commutator according to any one of claims 1 to 6, wherein the commutator is fixed to the rotating shaft through the axial hole of the annular insulator, and the lead wires of each of the winding elements are respectively electrically connected to the hook portion of the corresponding commutator segment of the commutator.

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