Installation method of high-overload-resistant DC brush motor commutator

Abstract

The invention discloses an installation method of an anti-high-overload DC brush motor commutator, and relates to the technical field of motor commutators. The method is used for solving the problem that in the prior art, installation methods of traditional commutators in some high-end application fields cannot meet the requirements for miniaturization and light weight of a direct-current brush motor and high overload resistance and reliability of the motor at the same time. The method comprises the following steps: S1, determining the sizes of a central shaft hole and a rotor rotating shaft of a commutator 2 according to an assembly clearance value of the central shaft hole and the rotor rotating shaft of the commutator; and S2, installing the commutator. According to the invention, the reliability of the direct-current brush motor in a high-overload environment can be improved in a limited space under the condition that an additional complex structure is not added, and meanwhile, the requirements of miniaturization and light weight of the motor are met.

Description

Technical Field

[0001] The invention relates to the technical field of motor commutators, and in particular to a method for installing a commutator of a high overload resistant direct current brush motor. Background Art

[0002] Some high-end application fields require brushed DC motors to have high overload resistance and reliability, while also meeting the requirements of miniaturization and lightweight. However, miniaturization and lightweight mean that complex structures cannot be used in small spaces. A common method is to drill holes in the commutator and fix it with multiple bolts around it. However, this method increases the weight of the commutator and does not meet the lightweight requirements. At the same time, the holes will also weaken the reliability of the commutator. Another method is to use an interference fit between the commutator and the shaft, and external force is required to press the commutator onto the shaft. This method will generate large internal stress, and the commutator and shaft are very easy to break in a high overload impact environment. Summary of the invention

[0003] In view of the above analysis, the present invention aims to provide a method for installing a commutator of a DC brush motor that is resistant to high overload, so as to solve the problem that the installation method of traditional commutators in some high-end application fields in the prior art cannot simultaneously meet the requirements of miniaturization and lightweight of the DC brush motor and the high overload resistance and reliability of the motor.

[0004] The purpose of the present invention is mainly achieved through the following technical solutions:

[0005] A method for installing a commutator of a high overload resistant DC brushless motor comprises the following steps:

[0006] Step S1: determining the size of the central axis hole of the commutator 2 and the rotor shaft according to the assembly clearance value between the central axis hole of the commutator and the rotor shaft;

[0007] Step S2: Install the commutator.

[0008] Furthermore, in step 1, the assembly clearance value between the commutator and the rotor shaft is 0.012 mm to 0.018 mm.

[0009] Furthermore, the step 2 specifically includes:

[0010] Step S2.1: machining a resin storage tank on the mounting surface of the rotor shaft and filling the tank with resin;

[0011] Step S2.2: Install the commutator into the rotating shaft using a positioning fixture and a clamping device.

[0012] Furthermore, the glue storage tank is a spiral tank.

[0013] Furthermore, the ratio of the groove depth of the glue storage groove to the diameter of the rotor shaft mounting end is 1:25 to 1:20; the ratio of the groove width to the groove depth of the glue storage groove is 0.6, and the helix angle of the glue storage groove is 20°.

[0014] Furthermore, the step S2.2 specifically includes:

[0015] Step S2.2.1: Fix the rotating shaft using a positioning fixture and a clamping device, and assemble the commutator;

[0016] Step S2.2.2: Clean up the excess resin glue, let it stand for 24 hours, and the DG-2 resin adhesive will solidify, completing the installation of the commutator.

[0017] Furthermore, in step S2.2.1,

[0018] The positioning tooling includes an upper die and a lower die; the clamping device includes an upper workbench, a lower workbench and a guide structure; the upper workbench is provided with a central through hole, and the upper die can move up and down in the central through hole; the guide structure is used to provide guidance for the movement of the upper die;

[0019] The lower workbench is used to fix the lower mold, and a first conical surface, a first cylindrical surface, a second conical surface and a second cylindrical surface are coaxially arranged inside the upper mold.

[0020] Furthermore, during assembly, the axis of the first conical surface coincides with the axis of the rotating shaft and stops at the end of the rotating shaft; the diameter of the first cylindrical surface is the same as the diameter of the shaft section matched with the commutator; one end of the first cylindrical surface is connected to the first conical surface, and the other end is connected to the second conical surface; the other end of the second conical surface is arranged at the end of the commutator; the diameter of the second cylindrical surface is the same as the outer diameter of the commutator;

[0021] A positioning flange is arranged on the second cylindrical surface. The positioning flange has the same shape as the groove outside the commutator and is used for positioning the commutator.

[0022] Furthermore, the step 2.2.1 is specifically as follows: fixing the rotating shaft with the lower die; installing the commutator into the second cylindrical surface of the upper die, so that the elastic positioning flange is stuck into the groove outside the commutator;

[0023] Operate the clamping device, and under the guidance of the guide structure, press the upper die down to assemble the commutator to the rotating shaft.

[0024] Furthermore, in step S2.2.1, specifically:

[0025] The single-side gap between the commutator mounting surface and the shaft mounting surface is ≥0.006mm; the installation distance between the commutator and the end of the shaft close to the commutator is ≥3mm.

[0026] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0027] (1) Compared with the prior art, the commutator and the rotor shaft of the present invention adopt a small assembly clearance between 0.012mm and 0.018mm, which avoids the traditional interference fit that requires external force to press the commutator onto the shaft, generating large internal stress, and the commutator is very easy to break in a high overload impact environment; it also avoids the loosening and displacement of components during the impact process when the large clearance fit is used, and improves the connection stability between the components. Small clearance fit can reduce the impact stress concentration between the commutator and the shaft, help to disperse the impact load, make the force between the components under the impact load more evenly distributed, effectively absorb and disperse energy; can reduce impact deformation; in the case of repeated impact, small clearance fit helps to reduce the cumulative damage caused by excessive clearance.

[0028] (2) Compared with the prior art, the present invention provides a spiral glue storage groove at the joint surface of the rotor shaft and the commutator to increase the contact area and bonding force between the resin and the interface, thereby improving the impact resistance of the joint. The ratio of the groove depth of the spiral groove to the diameter of the rotor shaft mounting end is set to 1:25 to 1:20, thereby improving the impact resistance without damaging the shaft strength. The groove width and groove depth ratio of the spiral groove is set to 0.6, so that the glue can be evenly distributed in the glue storage groove, avoiding stress concentration areas during impact; the spiral angle of the glue storage groove is set to 20°, the absolute value of the cross damping is maximized, and the impact resistance of the joint is enhanced.

[0029] (3) Compared with the prior art, in order to improve the high-precision concentricity of the commutator and the rotating shaft and reduce the additional stress caused by misalignment and reduce the overload resistance, the positioning tool in the present invention coaxially sets a first conical surface, a first cylindrical surface, a second conical surface and a second cylindrical surface. The first conical surface starts from the extended axis of the rotating shaft, and the conical surface is used to position the commutator, ensure the matching accuracy between the rotating shaft and the commutator, optimize the vibration of the rotor and reduce the gyroscopic torque effect generated by the rotor, so as to ensure that the motor can run efficiently, safely, reliably and stably.

[0030] (4) In the present invention, after the commutator is installed on the rotor shaft, the rotor assembly is installed on the motor housing. The motor rotor rotates at high speed during operation. When a high overload impact is applied, the rotor and the commutator will oscillate inside the motor housing. At the extreme position, the end of the rotor shaft will contact the rear cover of the motor, and the commutator will move with the rotor. To ensure that the rotor rotates without jamming, the single-sided gap between the commutator mounting surface and the shaft mounting surface is ≥0.006mm; the installation distance between the commutator and the end of the shaft is ≥3mm.

[0031] (5) In order to make the connection between the commutator and the rotor shaft resistant to impact, resin is provided in the resin storage tank as a shock absorbing material to absorb and disperse the load during impact.

[0032] Other features and advantages of the present invention will be described in the following description, and part of them will become obvious from the description, or will be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings are only for the purpose of illustrating the particular invention and are not to be considered as limiting the invention. The same reference symbols denote the same components throughout the accompanying drawings.

[0034] Figure 1 is an installation flow chart of a specific embodiment;

[0035] Figure 2 is a schematic diagram of the commutator structure of a specific embodiment;

[0036] Figure 3 is a schematic structural diagram of a rotor shaft in a specific embodiment;

[0037] Figure 4 It is a schematic diagram of the structure of the clamping device and the positioning tooling of a specific embodiment;

[0038] Figure 5 It is a structural schematic diagram of an upper mold in a specific embodiment;

[0039] Figure 6 It is a schematic diagram of the high overload impact resistance test structure of a specific embodiment.

[0040] Reference numerals:

[0041] 1-shaft, 101-glue storage tank, 2-commutator, 201-groove, 3-positioning tooling, 301-upper die, 3011-first conical surface, 3012-first cylindrical surface, 3013-second conical surface, 3014-second cylindrical surface, 3015-positioning flange, 302-lower die, 4-clamping device, 401-upper workbench, 402-lower workbench, 403-guide rod, 404-sleeve, 405-spring. DETAILED DESCRIPTION

[0042] The preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of the present invention and are used to explain the principles of the present invention together with the present invention.

[0043] This embodiment provides a method for installing a commutator of a DC brushless motor with high overload resistance, such as Figure 1 As shown, the following steps are included:

[0044] Step S1: determining the size of the central axis hole of the commutator 2 and the rotor shaft 1 according to the assembly clearance value between the commutator 2 and the rotor shaft 1;

[0045] Step S2: Install the commutator 2.

[0046] The step S1 specifically includes:

[0047] Step S1.1: Determine the assembly clearance value between the central axis hole of the commutator 2 and the rotor shaft 1;

[0048] The commutator 2 and the rotor shaft 1 are matched by a selection method. Specifically, the assembly clearance between the central axis hole of the commutator 2 and the rotor shaft 1 is between 0.012 mm and 0.018 mm.

[0049] Compared with the prior art, the commutator 2 and the rotor shaft 1 are matched with a small clearance, which avoids the traditional interference fit that requires the use of external force to press the commutator 2 onto the shaft, generating large internal stress, and the commutator 2 and the rotor shaft 1 are very easy to break in a high overload impact environment; it also avoids the loosening and displacement of the commutator 2 during the impact process when the large clearance fit is used, and improves the connection stability between the commutator 2 and the shaft 1. The small clearance fit can reduce the impact stress concentration between the commutator 2 and the shaft 1, help disperse the impact load, optimize the interaction between the shaft 1 and the commutator 2, make the force between the shaft 1 and the commutator 2 more uniform under the impact load, and effectively absorb and disperse energy; it can increase the overall rigidity of the structure and reduce impact deformation; in the case of repeated impacts, the small clearance fit helps to reduce the cumulative damage caused by excessive clearance.

[0050] Step S1.2: Determine the dimensions and tolerances of the rotor shaft 1 and the commutator 2.

[0051] like Figure 2 As shown, the commutator 2 has a center hole. In this embodiment, the size of the center hole of the commutator 2 is The dimensions of the mounting area between the rotating shaft 1 and the commutator 2 are The fitting clearance is 0.016mm.

[0052] The step S2 specifically includes:

[0053] Step S2.1: machining a resin storage tank 101 on the rotor shaft 1 and filling it with resin;

[0054] Step S2.2: Install the commutator 2 into the rotating shaft 1, and the single-side gap between the commutator mounting surface and the rotating shaft mounting surface is ≥0.006mm.

[0055] Step S2.1.1: Determine the mounting surface of the rotor shaft 1;

[0056] like Figure 3 As shown, the mounting surface of the rotor shaft 1 is close to the end of the rotor shaft 1 to the shoulder of the rotor shaft 1 .

[0057] Step S2.1.2: machining a glue storage groove 101 on the mounting surface of the rotor shaft 1;

[0058] Specifically, the glue storage groove 101 is a spiral groove. The glue storage groove 101 is set as a spiral groove, which can increase the contact area between the resin and the interface, enhance the bonding force between the resin and the interface, and improve the impact resistance of the joint between the commutator and the rotating shaft.

[0059] If the depth of the glue storage tank 101 is too large, the bearing capacity of the rotating shaft 1 will be weakened. The ratio of the depth of the glue storage tank 101 to the diameter of the mounting end of the rotor rotating shaft 1 is set to 1:25-1:20.

[0060] According to the influence of the spiral groove on the dynamic coefficient of the liquid film, when the ratio of the groove width to the groove depth is 0.6, the glue can be evenly distributed in the glue storage groove 101 and has good fluidity, so that when subjected to force, the stress can be evenly distributed, avoiding stress concentration areas and improving the impact resistance of the connection parts; when the spiral angle of the spiral groove is 20°, the absolute value of the cross damping in both angular directions is the largest, so the ability to absorb vibration energy is the largest, and the impact resistance is stronger. Therefore, the ratio of the groove width to the groove depth of the glue storage groove 101 is set to 0.6, and the spiral angle is 20°.

[0061] Compared with the prior art, this embodiment sets a spiral glue storage groove 101 at the joint surface of the rotor shaft 1 and the commutator 2 to increase the contact area and bonding force between the resin and the interface, and improve the impact resistance of the connection. The ratio of the groove depth of the spiral groove to the diameter of the mounting end of the rotor shaft 1 is set to 1:25 to 1:20, which improves the impact resistance without damaging the shaft strength. The groove width and groove depth ratio of the spiral groove is set to 0.6, so that the glue can be evenly distributed in the glue storage groove 101, and stress concentration areas are avoided during impact; the spiral angle of the glue storage groove 101 is set to 20°, and the absolute value of the cross damping is maximized, so that the impact resistance of the connection is enhanced.

[0062] It should be noted that the processing direction of the glue storage tank 101 is the same as the installation direction of the commutator 2 , that is, from the side close to the end of the rotor shaft 1 to the shoulder of the rotor shaft 1 .

[0063] Step S2.1.3: Filling the resin storage tank 101 with resin.

[0064] The step S2.1.3 specifically includes:

[0065] Step S2.1.3.1: Select resin;

[0066] In order to make the connection between the commutator 2 and the rotor shaft 1 resistant to impact, a shock-absorbing material is provided in the resin storage tank 101 to absorb and disperse the load during impact. The shock-absorbing material should have high elasticity and damping characteristics and mechanical properties, and have a low density to meet the requirements of light weight. In this embodiment, a resin with high viscosity, elasticity and damping characteristics and mechanical properties is selected as the shock-absorbing material.

[0067] In this embodiment, the selected resin is DG-2 epoxy resin. As an alternative to this embodiment, it can also be polycarbonate, ABS resin or PBT resin.

[0068] DG-2 epoxy resin has high viscosity and can bond the commutator and rotor shaft. The viscosity of DG-2 resin is 300-700Pa·s at room temperature. It has high elasticity and can absorb and disperse vibration and impact energy when impacted or vibrated, and quickly restore to its original state. It has a high damping coefficient and reaches its maximum value in the glass transition zone. It can absorb vibration energy to the maximum extent, reduce vibration, and has a large impact resistance. With good mechanical properties, the shear strength of the selected resin is ≥18Mpa and the peel strength is ≥39.2N / cm, which can withstand the expected load and impact.

[0069] Compared with the prior art, the present embodiment fills the resin storage tank with shock-absorbing material resin, and connects the commutator 2 and the rotor shaft 1 through the high viscosity of the resin. The high elasticity of the resin enables the connection to absorb and disperse vibration and impact energy when it is impacted or vibrated; the high damping coefficient can reduce vibration and has a large impact resistance. The shear strength of the resin is ≥18Mpa, the peel strength is ≥39.2N / cm, and the good mechanical properties can withstand the expected load and impact.

[0070] Step S2.1.3.2: Inject resin into the resin storage tank 101.

[0071] First, clean the glue storage tank 101 , and use a syringe to extract DG-2 resin and inject it into the glue storage tank 101 of the rotor shaft 1 .

[0072] It should be noted that the DG-2 resin should be injected slowly to exhaust air, so as to ensure that the DG-2 adhesive can form a complete adhesive layer in the adhesive storage tank 101 .

[0073] In the step 2.2, the commutator 2 is installed into the rotating shaft 1 by using a positioning tool, which specifically includes:

[0074] Step S2.2.1: fix the rotating shaft 1 by using the clamping device 4 and the positioning tool 3, and assemble the commutator 2;

[0075] In order to ensure high-precision concentricity between the commutator 2 and the rotating shaft 1 and reduce the additional stress caused by misalignment that reduces the overload resistance, the present embodiment uses a positioning fixture 3 and a clamping device 4 to assemble the commutator 2 .

[0076] like Figure 4 As shown, the positioning tool 3 includes an upper mold 301 and a lower mold 302 .

[0077] The clamping device 4 includes an upper workbench 401, a lower workbench 402 and a guide structure 403. The guide structure 403 includes a guide rod 4031, a sleeve 4032 and a spring 4033. A guide rod 4031, a sleeve 4032 and a spring 4033 are arranged between the upper workbench 401 and the lower workbench 402 to guide the downward movement of the upper die 301. The upper die 301 is provided with an external thread on the outside, and a threaded through hole is provided in the middle of the upper workbench 401 to install the upper die 301.

[0078] The lower die 302 is fixed to the lower workbench 402 . A long cylindrical groove is provided inside the lower die 302 for fixing the rotating shaft 1 . The lower die 302 accommodates the shaft section from the end away from the commutator 2 to the shaft shoulder step.

[0079] In order to improve the alignment between the commutator 2 and the rotating shaft 1, the upper die 301 is coaxially provided with a first conical surface 3011, a first cylindrical surface 3012, a second conical surface 3013 and a second cylindrical surface 3014. The axis of the first conical surface 3011 coincides with the axis of the rotating shaft 1, and the first conical surface 3011 ends at the end of the rotating shaft 1. The diameter of the first cylindrical surface 3012 is the same as the diameter of the shaft section matched with the commutator 2; one end of the first cylindrical surface 3012 is connected to the first conical surface 3011, and the other end is connected to the second conical surface 3013. The other end of the second conical surface 3013 is arranged at the end of the commutator 2; the diameter of the second cylindrical surface 3014 is the same as the outer diameter of the commutator 2.

[0080] Furthermore, if Figure 5 As shown, an elastic positioning flange 3015 is provided on the second cylindrical surface 3014 of the upper mold 301 . The positioning flange 3015 has the same shape as the groove 201 outside the commutator 2 and is used for positioning the commutator 2 .

[0081] During assembly, first insert the end of the shaft 1 away from the commutator 2 into the lower die 302 until it reaches the end face of the shaft shoulder; install the commutator 2 into the second cylindrical surface 3014 of the upper die 301, and make the elastic positioning flange 3015 snap into the groove 201 of the commutator 2 to fix the commutator 2. Screw the upper die 301 into the central threaded through hole of the upper workbench 401, operate the clamping device 4, and press the upper die 301 downward under the guidance of the guide structure 403 until the commutator 2 is assembled to the other end face that fits the shaft shoulder.

[0082] Compared with the prior art, the positioning fixture 3 in this embodiment coaxially sets the first conical surface 3011, the first cylindrical surface 3012, the second conical surface 3013 and the second cylindrical surface 3014. The first conical surface 3011 is set to start from the extended axis of the rotating shaft 1. The centering effect of the conical surface is used to improve the positioning accuracy of the commutator 2 and the rotating shaft 1, ensure the matching accuracy between the rotating shaft 1 and the commutator 2, optimize the vibration of the rotor and reduce the gyroscopic torque effect generated by the rotor, thereby ensuring that the motor can run efficiently, safely, reliably and stably.

[0083] The commutator 2 is installed on the shaft 1 and inspected under a high-magnification image tester to ensure that the single-side gap between the installation surface of the commutator 2 and the outer cylindrical surface of the shaft 1 is ≥ 0.006mm, and to ensure the uniformity of the amount of glue filled between the inner hole of the commutator 2 and the rotor shaft 1.

[0084] It should be noted that after the commutator 2 is installed on the rotor shaft 1, the rotor assembly is installed on the motor housing. The motor rotor rotates at high speed during operation. When a high overload impact is applied, the rotor and commutator 2 will oscillate inside the motor housing. At the extreme position, the end of the rotor shaft 1 will contact the rear cover of the motor, and the commutator 2 will move with the rotor. To ensure that the rotor rotates without jamming, the installation distance between the commutator 2 and the end of the shaft 1 is ≥3mm.

[0085] Step S2.2.2: Clean up the excess resin glue, let it stand for 24 hours, and the DG-2 resin adhesive will solidify, completing the installation of the commutator 2.

[0086] After the commutator 2 is installed using this method, the high overload resistance is greatly improved, and the reliability of high overload resistance reaches 100%. The assembled motor is installed on a steering gear and a high overload test is carried out. Figure 6 As shown, the high overload impact resistance is ≥18000g, and the safety factor of the structural strength is ≥2. The motor was tested for performance before and after the test, and the motor worked normally. After installing the commutator 2 using a small clearance fit and a glue storage tank 101, the high overload resistance of 13000-14000g of the traditional installation method is exceeded, solving the problem of improving the reliability of the DC brush motor in a high overload environment in a limited space without adding additional complex structures, while meeting the requirements of miniaturization and lightweight of the commutator 2.

[0087] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

Claims

1. A method for installing a commutator of a high overload resistant DC brushed motor, characterized in that: The following steps are involved: Step S1: determining the size of the central axis hole of the commutator (2) and the rotor shaft (1) according to the assembly clearance value between the central axis hole of the commutator (2) and the rotor shaft (1); Step S2: Install the commutator (2).

2. The installation method of the commutator of the high overload resistant DC brush motor according to claim 1 is characterized in that: In the step S1, the assembly clearance value between the commutator (2) and the rotor shaft (1) is 0.012 mm to 0.018 mm.

3. The installation method of the commutator of the high overload resistant DC brush motor according to claim 1 is characterized in that: The step S2 specifically includes: Step S2.1: machining a resin storage tank (101) on the mounting surface of the rotor shaft (1) and filling the tank with resin; Step S2.2: Use the positioning tool (3) to install the commutator (2) into the rotating shaft (1).

4. The installation method of the commutator of the high overload resistant DC brush motor according to claim 3 is characterized in that: The glue storage groove (101) is a spiral groove.

5. The method for installing a commutator of a DC brush motor with high overload resistance according to claim 4, characterized in that: The ratio of the groove depth of the glue storage groove (101) to the diameter of the mounting end of the rotor shaft (1) is 1:25 to 1:20; the ratio of the groove width to the groove depth of the glue storage groove (101) is 0.6; and the helix angle of the glue storage groove (101) is 20°.

6. The method for installing a commutator of a DC brush motor with high overload resistance according to claim 3, characterized in that: The step S2.2 specifically includes: Step S2.2.1: fix the rotating shaft (1) using the clamping device (4) and the positioning tool (3) and assemble the commutator (2); Step S2.2.2: Clean up the excess resin glue and let it stand for 24 hours to allow the DG-2 resin adhesive to solidify, completing the installation of the commutator (2).

7. The method for installing a commutator of a DC brush motor with high overload resistance according to claim 6, characterized in that: The positioning tool (3) comprises an upper die (301) and a lower die (302); the pressing device (4) comprises a guide structure (403); the guide structure (403) is used to provide guidance for the movement of the upper die (301); The upper mold (301) is coaxially provided with a first conical surface (3011), a first cylindrical surface (3012), a second conical surface (3013) and a second cylindrical surface (3014).

8. The method for installing a commutator of a DC brush motor with high overload resistance according to claim 7, characterized in that: During assembly, the axis of the first conical surface (3011) coincides with the axis of the rotating shaft (1) and stops at the end of the rotating shaft (1); the diameter of the first cylindrical surface (3012) is the same as the diameter of the shaft section that matches the commutator (2); one end of the first cylindrical surface (3012) is connected to the first conical surface (3011), and the other end is connected to the second conical surface (3013); the other end of the second conical surface (3013) is arranged at the end of the commutator (2); the diameter of the second cylindrical surface (3014) is the same as the outer diameter of the commutator (2); An elastic positioning flange (3015) is provided on the second cylindrical surface (3014); the positioning flange (3015) has the same shape as the groove (201) outside the commutator (2) and is used for positioning the commutator (2).

9. The method for installing a commutator of a DC brush motor with high overload resistance according to claim 8, characterized in that: The step 2.2.1 is specifically as follows: The lower die (302) fixes the rotating shaft (1); the commutator (2) is installed into the second cylindrical surface (3014) of the upper die (301), so that the elastic positioning flange (3015) is inserted into the groove (201) outside the commutator (2); The clamping device (4) is operated, and under the guidance of the guide structure (403), the upper mold (301) is pressed downward to assemble the commutator (2) to the rotating shaft (1).

10. The method for installing a commutator of a DC brush motor with high overload resistance according to claim 9, characterized in that: In the step S2.2.1, specifically: The single-side clearance between the mounting surface of the commutator (2) and the mounting surface of the rotating shaft (1) is ≥0.006 mm; and the mounting distance between the commutator (2) and the end of the rotating shaft (1) close to the commutator (2) is ≥3 mm.

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