A sleeveless commutator sunken DC servo motor rotor structure and method

Abstract

The present invention belongs to the field of motor design and process technology, and discloses a shaft sleeve-free commutator sunken DC servo motor rotor structure, the structure includes an armature winding, a rotor commutator, a rotor core, a rotor end piece and epoxy resin glue, and the rotor commutator, the rotor core and the rotor end piece are connected and arranged by epoxy resin glue. The structure of the present invention adopts a shaft sleeve-free design form, eliminating the metal rotor shaft sleeve, and the rotor core and the rotor end piece are directly connected and arranged, which ensures the processability while greatly reducing the rotor volume and weight, and can further increase the radial space of the core assembly. The armature winding space can be increased on the same axial length, and the number of winding turns can be increased, so that the motor can achieve greater mechanical properties under the same rotor size, and solve the problem that the high-precision drive system in a small space has strict requirements on the weight of the actuator rotor, and the carbon brush and the commutator are safe and reliable under long-term friction rotation.

Description

Technical Field

[0001] The invention belongs to the field of motor design and process technology, and relates to a sleeveless DC servo motor, in particular to a sleeveless commutator sunken DC servo motor rotor structure and method. Background Art

[0002] Compared with other motors, DC servo motors use brush mechanical commutation, have good mechanical properties and high operability, and are now widely used in military and civilian industries. The interior of the motor mainly consists of a stator (magnetic steel assembly), a rotor, a brush holder assembly, and a shaft structure. Traditional rotors are generally made of armature windings, core assemblies, commutators, and sleeves through welding, threading, and glue filling. As weapon systems in the fields of weapon guidance, aerospace, etc. develop towards miniaturization and lightweight, the volume, weight, and performance reliability of actuators are becoming increasingly important. Therefore, it is crucial to innovate the design of the rotor structure to achieve the design goals of a rotor structure with light weight, excellent performance, and high reliability. Summary of the invention

[0003] The purpose of the present invention is to overcome the deficiencies in the prior art and to provide a sleeveless commutator sunken DC servo motor rotor structure and method.

[0004] To achieve the above object, the technical solution adopted by the present invention is:

[0005] A sleeveless commutator sunken DC servo motor rotor structure, the structure comprising an armature winding, a rotor commutator, a rotor core, a rotor end piece and epoxy resin glue, wherein the rotor commutator, the rotor core and the rotor end piece are connected and arranged by epoxy resin glue;

[0006] The rotor core is arranged in the axial direction, and the two axial ends of the rotor core are closely connected and coaxially arranged with rotor end pieces, and the armature winding is closely wound on the rotor core, and the armature winding has coil connection terminals;

[0007] The rotor commutator is arranged in the radial direction, and the rotor commutator is inserted in the axial direction of the rotor core; the radial diameter of the rotor commutator is smaller than the radial diameter of the rotor core;

[0008] The rotor commutator is composed of a plurality of rotor commutator segments, a welding groove is provided at the tail end thereof, and the coil terminal is welded to the welding groove; the plurality of rotor commutator segments are evenly spaced and arranged in a circumferential direction, and two adjacent rotor commutator segments are connected and arranged by epoxy resin glue, and a chamfer groove is formed on the epoxy resin glue between two adjacent rotor commutator segments, the chamfer groove is arranged in a radial direction and is arranged on the outside of the rotor commutator, and the chamfer groove close to the outer surface of the commutator and the two adjacent rotor commutator segments are both formed with a chamfer.

[0009] Furthermore, the sinking distance of the rotor commutator should satisfy: the radial diameter d of the rotor core 铁芯 - Radial diameter d of the rotor commutator 换向器 =0.06mm.

[0010] Furthermore, the undercut depth h0 of the rotor commutator, i.e., the depth of the guide grooves in the radial direction, should satisfy: h0 = radial diameter d of the rotor core 铁芯 / 50;

[0011] The lead angle C of the rotor commutator should satisfy: C=υ*h0, where υ is an adjustment coefficient, generally ranging from 0.1 to 0.15.

[0012] Furthermore, the rotor core is made of stacked rotor punchings, and the rotor end sheets are coaxially connected to both ends of the rotor core.

[0013] Furthermore, the armature winding is formed by winding the coil using enameled wire according to the winding connection diagram and embedding it into the tooth slots of the rotor core.

[0014] Furthermore, the rotor core is made of precision alloy.

[0015] Furthermore, the rotor end piece is an insulating end piece, and the rotor end piece is made of epoxy resin hard laminate EPGC201.

[0016] Furthermore, the bottom layer material of the rotor commutator is selected as red copper and the surface is electroplated with a 0.01 mm gold layer.

[0017] The assembly method of the rotor structure as described above comprises the following steps:

[0018] The rotor end pieces are coaxially installed at the axial ends of the rotor core, and the two form a rotor core assembly; the coils are successively wound in the tooth slots of the rotor core according to the winding connection diagram to form an armature winding, and after shaping, the rotor commutator is inserted, and the coil terminal is welded to the welding groove of the rotor commutator, and epoxy resin glue is added for glue filling. The armature winding, rotor commutator and rotor core assembly are glued and formed using epoxy resin glue. After high-temperature curing and stabilization, the outer circle, end face and inner hole of the rotor are machined and finished, and the commutator and the insulating glue layer between them are engraved to form a rotor.

[0019] The advantages and effects achieved by the present invention are:

[0020] 1. The structure of the present invention includes an armature winding, a rotor commutator, a rotor core, a rotor end piece and epoxy resin glue. The structure of the present invention adopts a sleeveless design form, eliminating the metal rotor sleeve. The rotor core, the rotor end piece and the rotor commutator are directly connected and arranged, which ensures the processability while greatly reducing the rotor volume and weight, and can further increase the radial space of the core assembly. The armature winding space can be increased on the same axial length, and the number of winding turns can be increased, so that the motor can achieve greater mechanical properties under the same rotor size, and solves the problem of strict requirements on the weight of the actuator rotor in a small space high-precision drive system.

[0021] 2. The radial diameter of the rotor commutator is smaller than the radial diameter of the rotor core, that is, the rotor commutator of the present invention adopts a sunken design, so that the carbon powder worn off by the carbon brush under long-term rotation of the motor will not accumulate on the rotor core, avoiding the problem of abnormal insulation and ensuring the use effect; in addition, the rotor commutator of the present invention is provided with chamfer grooves and chamfers, and the chamfer structure is helpful to reduce the rotor commutation friction, improve the commutation efficiency and enhance the reliability of use. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic cross-sectional view of the structure of the motor rotor structure of the present invention;

[0023] Figure 2 It is a partial enlarged schematic diagram of the structure connection of the rotor structure of the motor of the present invention, namely, the rotor commutator segments, chamfer grooves, chamfers and epoxy resin glue;

[0024] Figure 3 It is a three-dimensional schematic diagram (front view) of an integral structural connection of the motor rotor structure of the present invention;

[0025] Figure 4 It is a three-dimensional schematic diagram (reverse side) of the overall structural connection of the motor rotor structure of the present invention. DETAILED DESCRIPTION

[0026] The present invention will be further described in detail below in conjunction with specific examples. The following examples are only illustrative and not restrictive, and the protection scope of the present invention cannot be limited thereto.

[0027] The raw materials used in the present invention, unless otherwise specified, are conventional commercial products, the methods used in the present invention, unless otherwise specified, are conventional methods in the art, and the quality of each substance used in the present invention is conventional quality. The structures, connection relationships, etc. not described in detail in the present invention can be understood as conventional technical means in the art.

[0028] A sleeveless commutator sunken DC servo motor rotor structure, such as Figures 1 to 4As shown, the structure includes an armature winding 1, a rotor commutator 2, a rotor core 3, a rotor end piece 4 and an epoxy resin glue 5, and the rotor commutator, the rotor core and the rotor end piece are connected and arranged by the epoxy resin glue;

[0029] The rotor core is arranged in the axial direction, and the two axial ends of the rotor core are closely connected and coaxially provided with rotor end pieces, and the armature winding is closely wound on the rotor core, and the armature winding has coil connection terminals (not shown in the figure);

[0030] The rotor commutator is arranged in the radial direction, and the rotor commutator is inserted along the axial direction of the rotor core; the radial diameter of the rotor commutator is smaller than the radial diameter of the rotor core; the radial diameter of the rotor commutator is smaller than the radial diameter of the rotor core, that is, the rotor commutator of the present invention adopts a sunken design, so that the carbon powder worn off by the carbon brush under long-term rotation of the motor will not accumulate on the rotor core, causing insulation abnormality problems, thereby ensuring the use effect.

[0031] The rotor commutator is composed of a plurality of rotor commutator segments 21, the tail end of which is provided with a welding groove (not shown in the figure), and the coil terminal is welded to the welding groove; the plurality of rotor commutator segments are evenly spaced and arranged in a circumferential direction, and two adjacent rotor commutator segments are connected and arranged by epoxy resin glue, and a chamfer groove 22 is formed on the epoxy resin glue between two adjacent rotor commutator segments, and the chamfer groove is arranged in a radial direction and is arranged on the outside of the rotor commutator, and a chamfer 23 is formed on the chamfer groove close to the outer surface of the commutator and two adjacent rotor commutator segments. In the present invention, the rotor commutator is provided with a chamfer groove and a chamfer, and a chamfer structure is adopted, which is beneficial to reducing rotor commutation friction, improving commutation efficiency, and enhancing reliability in use.

[0032] The structure of the present invention includes an armature winding, a rotor commutator, a rotor core, a rotor end piece and epoxy resin glue. The structure of the present invention adopts a sleeve-free design form, eliminating the metal rotor sleeve. The rotor core, the rotor end piece and the rotor commutator are directly connected and arranged, which ensures the processing feasibility while greatly reducing the rotor volume and weight, and can further increase the radial space of the core assembly. The armature winding space can be increased on the same axial length, and the number of winding turns can be increased, so that the motor can achieve greater mechanical properties under the same rotor size, and solves the problem of strict requirements on the weight of the actuator rotor in a high-precision drive system in a small space and safety and reliability under long-term friction rotation of the carbon brush and the commutator.

[0033] At the same time, the radial diameter of the rotor commutator is smaller than the radial diameter of the rotor core, that is, the rotor commutator of the present invention adopts a sunken design, so that the carbon powder worn off by the carbon brush under long-term rotation of the motor will not accumulate on the rotor core, causing insulation abnormalities, thereby ensuring the use effect; in addition, the rotor commutator of the present invention is provided with chamfer grooves and chamfers, and adopts a chamfer structure, which is beneficial to reducing rotor commutation friction, improving commutation efficiency, and enhancing reliability of use.

[0034] In this embodiment, the sinking distance of the rotor commutator should satisfy: the radial diameter d of the rotor core 铁芯 - Radial diameter d of the rotor commutator 换向器 =0.06mm.

[0035] In this embodiment, the undercut depth h0 of the rotor commutator, i.e., the depth of the guide grooves in the radial direction, should satisfy: h0 = radial diameter d of the rotor core 铁芯 / 50;

[0036] The lead angle C of the rotor commutator should satisfy: C=υ*h0, where υ is an adjustment coefficient, generally ranging from 0.1 to 0.15.

[0037] In this embodiment, the rotor core is made of rotor punchings, and the rotor end pieces are coaxially connected to both ends of the rotor core.

[0038] In this embodiment, the armature winding is formed by winding the coil using enameled wire according to the winding connection diagram and embedding it into the rotor core tooth slot, and the operation can be performed with reference to patent disclosure document 202110705078.3.

[0039] In this embodiment, the rotor core is made of a precision alloy, which has a high magnetic conductivity after heat treatment, and is helpful to improve the electromagnetic performance of the motor.

[0040] In this embodiment, the rotor end piece is an insulating end piece, which ensures the use effect. For example, the rotor end piece is made of epoxy resin hard laminate EPGC201. More preferably, in order to ensure the flatness of the E and F surfaces, lathe processing is performed, so the thickness of the rotor end piece needs to be appropriately increased. Generally, 0.5mm thick epoxy resin hard laminate EPGC201 is selected for processing.

[0041] In this embodiment, the bottom layer material of the rotor commutator is red copper and the surface is electroplated with a 0.01 mm gold layer. The use of metal with lower resistivity can reduce the contact resistance during the motor rotation and commutation process, reduce the current loss during the process, and increase the armature current in the working state.

[0042] In this embodiment, the epoxy resin glue is made of hard colloid material.

[0043] An assembly method of the above-mentioned sleeveless commutator sunken DC servo motor rotor structure comprises the following steps:

[0044] The rotor end pieces are coaxially installed at the axial ends of the rotor core, and the two form a rotor core assembly. According to the winding connection diagram, the coils are wound in the tooth slots of the rotor core assembly one by one to form the armature winding. After shaping, the rotor commutator is inserted, and the coil terminal is welded to the welding slot of the rotor commutator. Epoxy resin glue is added for glue filling. The armature winding, rotor commutator and rotor core assembly are glued and formed with epoxy resin glue. After high-temperature curing and stabilization, the outer circle, end face and inner hole of the rotor are machined and finished. The commutator and the insulating glue layer between them are engraved to form the rotor.

[0045] The working principle of the structure of the present invention can be:

[0046] The stator magnet emits magnetic lines of force, which return to the stator magnet (the other pole) after passing through the armature winding, forming a closed loop. According to Faraday's law of electromagnetic induction, when the external power supply is connected to the armature winding, electromagnetic force is generated. The commutation of the rotor commutator makes the current directions of the conductors with the same polarity of the stator magnet the same, and the current directions of the conductors with different polarities opposite. Therefore, all conductors generate torque in the same rotation direction, driving the rotor to rotate continuously.

[0047] The sunken design of the rotor commutator in the present invention prevents the carbon powder worn off by the carbon brush from accumulating on the rotor core during long-term rotation of the motor, causing insulation abnormality. The chamfered structure of the rotor commutator in the present invention is conducive to reducing rotor commutation friction, improving commutation efficiency, and enhancing reliability.

[0048] Although the embodiments of the present invention are disclosed for illustrative purposes, those skilled in the art will appreciate that various substitutions, changes 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.

Claims

1. A sleeveless commutator sunken DC servo motor rotor structure, characterized in that: The structure comprises an armature winding, a rotor commutator, a rotor core, a rotor end piece and epoxy resin glue, wherein the rotor commutator, the rotor core and the rotor end piece are connected and arranged by the epoxy resin glue; The rotor core is arranged in the axial direction, and the two axial ends of the rotor core are closely connected and coaxially arranged with rotor end pieces, and the armature winding is closely wound on the rotor core, and the armature winding has coil connection terminals; The rotor commutator is arranged in the radial direction, and the rotor commutator is inserted in the axial direction of the rotor core; the radial diameter of the rotor commutator is smaller than the radial diameter of the rotor core; The rotor commutator is composed of a plurality of rotor commutator segments, and a welding groove is provided at the tail end thereof; the plurality of rotor commutator segments are evenly spaced and arranged in a circumferential direction, and two adjacent rotor commutator segments are connected and arranged by epoxy resin glue, and a chamfer groove is formed on the epoxy resin glue between two adjacent rotor commutator segments, and the chamfer groove is arranged in a radial direction and on the outside of the rotor commutator, and the chamfer groove close to the outer surface of the commutator and two adjacent rotor commutator segments are formed with a chamfer.

2. The sleeveless commutator sunken DC servo motor rotor structure according to claim 1 is characterized in that: The sinking distance of the rotor commutator should satisfy: the radial diameter d of the rotor core 铁芯 - Radial diameter d of the rotor commutator 换向器 =0.06mm.

3. The sleeveless commutator sunken DC servo motor rotor structure according to claim 1, characterized in that: The engraved depth h0 of the rotor commutator, i.e. the depth of the angle groove in the radial direction, should satisfy: h0 = radial diameter d of the rotor core 铁芯 / 50; The lead angle C of the rotor commutator should satisfy: C=υ*h0, where υ is an adjustment coefficient and its value range is 0.1~0.

15.

4. The sleeveless commutator sunken DC servo motor rotor structure according to claim 1, characterized in that: The rotor core is made of stacked rotor sheets, and the rotor end sheets are coaxially connected to the two ends of the rotor core.

5. The sleeveless commutator sunken DC servo motor rotor structure according to claim 1, characterized in that: The armature winding is formed by winding a coil using enameled wire according to a winding connection diagram and embedding it into the tooth slots of the rotor core.

6. The sleeveless commutator sunken DC servo motor rotor structure according to claim 1, characterized in that: The rotor core is made of precision alloy.

7. The sleeveless commutator sunken DC servo motor rotor structure according to claim 1, characterized in that: The rotor end pieces are insulating end pieces.

8. The sleeveless commutator sunken DC servo motor rotor structure according to claim 7, characterized in that: The rotor end piece is made of epoxy resin hard laminate EPGC201.

9. The sleeveless commutator sunken DC servo motor rotor structure according to any one of claims 1 to 8, characterized in that: The bottom material of the rotor commutator is red copper with a 0.01 mm gold layer electroplated on the surface.

10. The method for assembling a rotor structure according to any one of claims 1 to 9, characterized in that: The steps include: The rotor end pieces are coaxially installed at the axial ends of the rotor core, and the two form a rotor core assembly; the coils are successively wound in the tooth slots of the rotor core assembly according to the winding connection diagram to form an armature winding, and after shaping, the rotor commutator is inserted, and the coil connection terminals are welded to the welding grooves of the rotor commutator, and epoxy resin glue is added for glue filling. The armature winding, rotor commutator and rotor core assembly are glued and formed using epoxy resin glue. After high-temperature curing and stabilization, the rotor outer circle, end face and inner hole are machined and finished, and the commutator and the insulating glue layer between them are engraved to form a rotor.

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