An auxiliary device and method for forming the armature of a disc-type coreless brushed motor

Abstract

This invention relates to an auxiliary device and method for forming the armature of a disc-type coreless brushed motor. The device includes a base plate, an upper cover plate, a wire divider ring, an outer ring, positioning pins, bolts, and nuts. The upper cover plate is coaxially aligned with the base. The wire divider ring and outer ring are respectively installed between the upper cover plate and the base, located inside and outside the upper and lower annular positioning platforms, respectively, so that the upper and lower annular positioning platforms, the wire divider ring, and the outer ring form a forming cavity that matches the set shape of the armature. Positioning pins for limiting the individual trapezoidal windings of the armature are inserted into each positioning pin hole on the base plate. Several corresponding through holes are formed on the center and outer circumference of the base plate and the upper cover plate, and the two are fastened together by bolts and nuts. The disc-type armature winding produced by this invention has a uniform distribution and high forming accuracy. In addition, the wire divider ring effectively separates and protects the individual winding leads, facilitating wiring.

Description

Technical Field

[0001] This invention belongs to the field of motor manufacturing technology, specifically relating to an auxiliary device and method for forming the armature of a disc-type coreless brushed motor. Background Technology

[0002] Disc-type coreless brushed torque motors possess a series of advantages, including small axial structural dimensions, wide speed range, ability to operate continuously in stall or low-speed conditions while outputting high torque, low static friction torque, low inertia, and low electrical time constant. They are widely used in various automatic control fields and serve as the actuator for stabilizing platforms in inertial navigation systems. A disc-type permanent magnet DC brushed torque motor consists of a housing, stator, and rotor. The rotor comprises, from the center outwards, a coaxially fixed bushing, a commutator assembly, and a disc-type coreless rotor armature. The disc-type coreless rotor armature is formed by pressing coaxially radially evenly distributed double-layered trapezoidal windings. The two leads at the lower end of each trapezoidal winding are connected with the same commutator pitch to the upper end of radially evenly distributed commutator segments fixed on the insulating bushing.

[0003] There are two common methods for manufacturing the armature of a disc-type coreless motor: one is direct potting, and the other is pressing individual windings first, then assembling them and followed by potting or impregnation for curing. The former, direct potting, is simple to operate, but during the vacuuming process, the windings and leads inevitably shift, affecting manufacturing accuracy. Furthermore, the fixed positions of the winding leads after potting make subsequent commutator connection difficult. The latter method, pressing individual windings first and then connecting multiple centralized independent windings in series and parallel, suffers from numerous and unfixed connecting wires between windings, complex processes, difficult operation, and low production efficiency. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an auxiliary device and method for forming the armature of a disc-type coreless brushed motor, which can improve forming accuracy, facilitate subsequent wiring, improve production efficiency and reduce production costs.

[0005] One of the above-mentioned objectives of the present invention is achieved through the following technical solution:

[0006] An auxiliary device for forming the armature of a disc-type coreless brushed motor, characterized in that it includes a base plate, an upper cover plate, a wire guide ring, an outer ring, positioning pins, bolts, and nuts;

[0007] The base plate is a disc-shaped structure. A lower annular positioning platform for placing the winding is provided on the upper surface of the base plate. A lower protruding ring is provided at the middle of the upper end of the lower annular positioning platform. Both radial edges of the lower protruding ring are rounded. A number of pin holes distributed along the circumference are made at the rounded corners on both sides.

[0008] The upper cover plate has a disc-shaped structure. An upper annular positioning platform for placing the winding is formed on the lower surface of the upper cover plate. An upper protruding ring is provided in the middle part of the upper annular positioning platform. Both radial edges of the upper protruding ring are rounded.

[0009] The upper half of the wire distribution ring has several lead fixing grooves distributed radially along the circumference for placing individual winding leads. The outer circle dimension of the wire distribution ring matches the inner circle dimension of the corresponding annular positioning platform of the base plate and the upper cover plate. The wire distribution ring is made of polytetrafluoroethylene material.

[0010] The inner circle dimension of the outer ring matches the outer circle dimension of the annular positioning platform of the base plate and the upper cover plate, and the axial dimension of the outer ring is greater than the axial dimension of the dividing ring.

[0011] The upper cover plate is coaxially aligned with the base. The wire divider ring and the outer ring are respectively installed between the upper cover plate and the base, located on the inner side of the upper and lower annular positioning platforms and on the outer side of the upper and lower annular positioning platforms, so that the upper annular positioning platform, the lower annular positioning platform, the wire divider ring and the outer ring form a molded cavity that matches the set shape of the armature. A positioning pin for limiting the individual trapezoidal winding of the armature is inserted into each positioning pin hole.

[0012] Several through holes are made at the center and outer circumference of the base plate and the top cover plate, respectively, and bolts and nuts are used to fasten the two together.

[0013] Furthermore, an annular groove is provided on the lower surface of the base plate at the position corresponding to the two rings of pin holes, and the width of the annular groove is greater than the diameter of the positioning pin hole.

[0014] The second objective of this invention is achieved through the following technical solution:

[0015] A forming method using the above-mentioned disc-type coreless brushed motor armature forming auxiliary device, the invention point of which includes the following steps:

[0016] Step 1: Based on the external dimensions of the armature to be formed, fabricate forming auxiliary tooling of corresponding dimensions;

[0017] Step 2: Apply a thin layer of silicone grease to the contact surfaces of the upper cover plate, outer ring, base plate and armature trapezoidal winding, as well as the surface of the positioning pins; install the outer ring and branch ring on both sides of the lower annular positioning platform on the base plate, and insert all the positioning pins into the pin holes on the base plate.

[0018] Step 3: Place several pre-wound trapezoidal windings one by one on the raised ring of the base plate with the locating pins inserted, according to the designed winding unfolding diagram. Each winding is fitted with the corresponding number of outer and inner locating pins according to the pitch. In this way, arrange all the windings into a double-layer wave chain structure.

[0019] Step 4: Place the lead wire of each trapezoidal winding into the lead wire fixing groove of the corresponding branch ring;

[0020] Step 5: After all the trapezoidal windings are placed, apply a small amount of acetal adhesive to bond them together; then align the upper annular positioning platform of the upper cover plate with the inner circle of the outer ring and the outer circle of the positioning ring, and align the upper protruding ring of the upper cover plate with the lower protruding ring of the bottom plate, and press it to the set size with a press.

[0021] Step 6: Use bolts to tighten nuts through several corresponding through holes on the center and outer circumference of the base plate and the top cover plate to achieve the clamping and fixing of all trapezoidal windings and auxiliary forming devices. Remove all positioning pins from the groove on the lower surface of the base plate.

[0022] Step 7: Place the device containing all the trapezoidal windings into an oven to dry and cure.

[0023] Step 8: After curing and cooling, disassemble the molding auxiliary device and remove the molded armature.

[0024] The advantages and positive effects of this invention are as follows:

[0025] 1. This invention utilizes inner and outer positioning pins to achieve uniform distribution of trapezoidal windings in the circumferential direction, resulting in good consistency and high positional indexing accuracy; it utilizes the upper cover plate, bottom plate, and outer ring to achieve precise control of the end dimensions and air gap dimensions of the disc armature windings, resulting in uniform distribution and high forming accuracy of the manufactured disc armature windings.

[0026] 2. The present invention uses a wire separator ring made of polytetrafluoroethylene to effectively separate and protect individual winding leads, which facilitates the connection of the commutator according to the design scheme after the armature is formed, and makes the wiring easier.

[0027] 3. The components of the molding auxiliary device of the present invention have simple structures, are easy to process, and have low production costs.

[0028] 4. The molding method of the present invention is simple to operate, has high production efficiency, and is applicable to various curing processes such as subsequent potting and impregnation. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the use of the device of the present invention;

[0030] Figure 2This is a three-dimensional schematic diagram of the winding assembly of the present invention;

[0031] Figure 3 This is a schematic diagram of a coreless disc armature.

[0032] In the diagram: 1. Armature; 1-1. Trapezoidal winding; 2. Upper cover plate; 2-1. Upper annular positioning platform; 2-2. Upper raised ring; 3. Branching ring; 3-1. Lead wire fixing groove; 4. Outer ring; 5. Bolt; 6. Nut; 7. Base plate; 7-1. Lower annular positioning platform; 7-2. Lower raised ring; 7-3. Groove; 8. Positioning pin. Detailed Implementation

[0033] The structure of the present invention will be further described below with reference to the accompanying drawings and embodiments. It should be noted that these embodiments are descriptive and not limiting.

[0034] Please refer to the following: An armature forming auxiliary device for a disc-type coreless brushed motor. Figures 1-3 Its invention points are: mainly including base plate 7, top cover plate 2, dividing ring 3, outer ring 4, positioning pin 8, bolt 5, and nut 6.

[0035] The base plate has a disc-shaped structure. On its upper surface, there is a lower annular positioning platform 7-1 for placing the winding. A lower raised ring 7-2 is located at the middle of the upper end of the lower annular positioning platform. Both radial edges of the lower raised ring have rounded corners, and corresponding to the rounded corners on both sides, several pin holes are distributed circumferentially. On the lower surface of the base plate, corresponding to the positions of the two rings of pin holes, there are annular grooves 7-3. The width of the grooves is larger than the diameter of the positioning pin holes, facilitating the removal of the positioning pins after the winding has been shaped.

[0036] The upper cover plate has a disc-shaped structure, matching the shape of the base plate. An upper annular positioning platform 2-1 for placing the winding is formed on the lower surface of the upper cover plate. An upper protruding ring 2-2 is located in the middle of the upper annular positioning platform, and both radial edges of the upper protruding ring have rounded corners. All the aforementioned characteristic dimensions are the same as the corresponding characteristic dimensions on the base plate. That is, the outer diameter of the upper cover plate is equal to the outer diameter of the base plate; the inner and outer diameters and height of the lower annular positioning platform are consistent with the inner and outer diameters and height of the upper annular positioning platform, respectively; the inner and outer diameters and height of the lower protruding ring are consistent with the inner and outer diameters and height of the upper protruding ring, respectively; and the rounded corners on both sides of the lower protruding ring have the same values ​​as the rounded corners on both sides of the upper protruding ring.

[0037] The upper half of the wire distribution ring has several lead fixing slots distributed radially along the circumference for placing individual winding leads. The outer circle dimension of the wire distribution ring matches the inner circle dimension of the annular positioning platform of the base plate and the upper cover plate. The wire distribution ring is made of polytetrafluoroethylene material to prevent it from sticking to other parts and windings during the bonding process, and can effectively separate and protect the winding leads.

[0038] The inner circle dimension of the outer ring matches the outer circle dimension of the annular positioning platform of the base plate and the top cover plate, and the axial dimension of the outer ring is greater than the axial dimension of the dividing ring.

[0039] The bottom plate and the top cover plate have several through holes at their respective centers and outer circumferences, which are fastened together by bolts.

[0040] A method for forming the armature of a disc-type coreless brushed motor, the invention of which is: using the above-mentioned forming auxiliary tooling, including the following steps:

[0041] Step 1: Based on the external dimensions of the armature to be formed, fabricate forming auxiliary tooling of corresponding dimensions;

[0042] Step 2: Apply a thin layer of silicone grease to the contact surfaces of the upper cover plate 2, outer ring 4, base plate 7 and the trapezoidal winding 1-1 of armature 1, as well as the surface of the positioning pins 8, to facilitate demolding. Install the outer ring 4 and the branch ring 3 on both sides of the lower annular positioning platform 7-1 on the base plate 7, and insert all the positioning pins 8 into the pin holes on the base plate 7.

[0043] Step 3: Place several pre-wound trapezoidal windings 1-1 one by one on the lower protruding ring 7-2 of the base plate 7 with the positioning pins 8 inserted, according to the designed winding unfolding diagram. Each winding 1-1 is fitted with the corresponding number of outer and inner positioning pins according to the pitch. In this way, all the windings are arranged into a double-layer wave chain structure.

[0044] Step 4: Place the lead wire of each trapezoidal winding 1-1 into the lead wire fixing groove 3-1 of the corresponding branch ring 3;

[0045] Step 5: After all trapezoidal windings 1-1 are placed, apply a small amount of acetal adhesive to bond them together; then align the upper annular positioning platform 2-1 of the upper cover plate 2 with the inner circle of the outer ring 4 and the outer circle of the positioning ring 3, and align the upper protruding ring 2-2 of the upper cover plate 2 with the lower protruding ring 7-2 of the base plate 7 and cover it with a press to the set size.

[0046] Step 6: Use bolts 5 through several through holes on the center and outer circumference of the base plate 7 and the top cover plate 2, tighten nuts 6, and realize the clamping and fixing of all trapezoidal windings 1-1 with the auxiliary forming device. Remove all positioning pins 8 from the groove 7-3 on the lower surface of the base plate 7.

[0047] Step 7: Place the device containing all the trapezoidal windings 1-1 into an oven to dry and cure.

[0048] Step 8: After curing and cooling, disassemble the molding auxiliary device and remove the molded armature.

[0049] In summary, this invention designs a set of easy-to-operate and easy-to-process specialized forming auxiliary devices. These devices install, position, and press several pre-wound trapezoidal windings into an "I"-shaped disc armature, thus completing the forming of a coreless disc armature. The forming method of this invention has advantages such as high production efficiency and low production cost. The armature produced by this forming method has the advantages of high processing accuracy and strong versatility.

[0050] Although embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, alterations and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. An armature forming auxiliary device for a disc-type coreless brushed motor, characterized in that: Includes base plate, top cover plate, dividing ring, outer ring, positioning pins, bolts, and nuts; The base plate is a disc-shaped structure. A lower annular positioning platform for placing the winding is provided on the upper surface of the base plate. A lower protruding ring is provided at the middle part of the upper end of the lower annular positioning platform. Both radial edges of the lower protruding ring are rounded. A number of pin holes distributed along the circumference are made at the rounded corners on both sides. The upper cover plate has a disc-shaped structure. An upper annular positioning platform for placing the winding is formed on the lower surface of the upper cover plate. An upper protruding ring is provided in the middle part of the upper annular positioning platform. Both radial edges of the upper protruding ring are rounded. The upper half of the wire distribution ring has several lead fixing grooves distributed radially along the circumference for placing individual winding leads. The outer circle dimension of the wire distribution ring matches the inner circle dimension of the corresponding annular positioning platform of the base plate and the upper cover plate. The wire distribution ring is made of polytetrafluoroethylene material. The inner circle dimension of the outer ring matches the outer circle dimension of the annular positioning platform of the base plate and the upper cover plate, and the axial dimension of the outer ring is greater than the axial dimension of the dividing ring. The upper cover plate is coaxially aligned with the base. The wire divider ring and the outer ring are respectively installed between the upper cover plate and the base, located on the inner side of the upper and lower annular positioning platforms and on the outer side of the upper and lower annular positioning platforms, so that the upper annular positioning platform, the lower annular positioning platform, the wire divider ring and the outer ring form a molded cavity that matches the set shape of the armature. A positioning pin for limiting the individual trapezoidal winding of the armature is inserted into each positioning pin hole. Several through holes are made at the center and outer circumference of the base plate and the top cover plate, respectively, and bolts and nuts are used to fasten the two together.

2. The disc-type coreless brushed motor armature forming auxiliary device according to claim 1, characterized in that: An annular groove is provided on the lower surface of the base plate at the position corresponding to the two rings of pin holes. The width of the annular groove is greater than the diameter of the positioning pin hole.

3. A forming method using the above-mentioned disc-type coreless brushed motor armature forming auxiliary device, the inventive point of which is: including the following steps: Step 1: Based on the external dimensions of the armature to be formed, fabricate forming auxiliary tooling of corresponding dimensions; Step 2: Apply a thin layer of silicone grease to the contact surfaces of the upper cover plate, outer ring, base plate and armature trapezoidal winding, as well as the surface of the positioning pins; install the outer ring and branch ring on both sides of the lower annular positioning platform on the base plate, and insert all the positioning pins into the pin holes on the base plate. Step 3: Place several pre-wound trapezoidal windings one by one on the raised ring of the base plate with the locating pins inserted, according to the designed winding unfolding diagram. Each winding is fitted with the corresponding number of outer and inner locating pins according to the pitch. In this way, arrange all the windings into a double-layer wave chain structure. Step 4: Place the lead wire of each trapezoidal winding into the lead wire fixing groove of the corresponding branch ring; Step 5: After all the trapezoidal windings are placed, apply a small amount of acetal adhesive to bond them together; then align the upper annular positioning platform of the upper cover plate with the inner circle of the outer ring and the outer circle of the positioning ring, and align the upper protruding ring of the upper cover plate with the lower protruding ring of the bottom plate, and press it to the set size with a press. Step 6: Use bolts to tighten nuts through several corresponding through holes on the center and outer circumference of the base plate and the top cover plate to achieve the clamping and fixing of all trapezoidal windings and auxiliary forming devices. Remove all positioning pins from the groove on the lower surface of the base plate. Step 7: Place the device containing all the trapezoidal windings into an oven to dry and cure. Step 8: After curing and cooling, disassemble the molding auxiliary device and remove the molded armature.

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