A copper sheet for micro motor commutator and a micro motor commutator manufacturing process based on the copper sheet

Abstract

The application discloses a copper sheet for a micro motor commutator and a micro motor commutator preparation process based on the copper sheet, and belongs to the technical field of commutator preparation processes.The copper sheet comprises a long strip-shaped body, one end of the body is integrally formed with a claw part (2), and the width w1 of the claw part is smaller than the width w2 of the body.The process mainly comprises the following steps: (1) punching forming the copper sheet; (2) arranging the copper sheet; (3) injection molding; (4) solidification; (5) finishing; (6) detecting whether the appearance is qualified and packing and shipping; wherein the finishing tool body is: (a) turning an inner hole; (b) turning an outer circle; (c) milling a groove; (d) bending a hook; (e) leakage test; the application aims to provide a copper sheet for a micro motor commutator and a micro motor commutator preparation process based on the copper sheet, which are novel in design, ingenious in structure, can reduce the preparation process of the commutator and are used for preparing the micro motor commutator.

Description

Technical Field

[0001] This invention relates to a copper sheet for a commutator, and more specifically, to a copper sheet for a micromotor commutator. The invention also relates to a fabrication process for a micromotor commutator based on this copper sheet. Background Technology

[0002] The commutator, also called a rectifier, is an important component of the armature of DC motors and AC commutator motors. Its function is to change the direction of the armature winding current so that the direction of the electromagnetic torque remains unchanged. It is composed of copper plates evenly distributed on the edge of a ring insulator and is connected to an external power source through brushes.

[0003] Existing commutator manufacturing processes, such as Figure 1 As shown, the specific steps are as follows:

[0004] (1) Stamping: The process of stamping raw copper wire into individual copper sheets using precision molds; such as Figure 1 As shown in (a), the side notch is for positioning during subsequent milling.

[0005] (2) Arranging the sheets: After arranging the individual copper sheets in a specific shape using equipment, insert them into the rubber sleeve and fix them into a circle. For example... Figure 1 As shown in (b).

[0006] (3) Injection molding: The arranged sheets are pressed into the injection mold. The bakelite powder is melted and pressed into the mold using a hydraulic press under high temperature and pressure, forming the initial shape of the commutator. For example... Figure 1 As shown in (c).

[0007] (4) Curing: Place the semi-finished product in a high-temperature oven and bake it for 15-25 hours to cure it.

[0008] (5) Finishing, which includes the following processes:

[0009] (a) Inner hole: The inner hole is drilled to the specified size using a drill bit.

[0010] (b) Turning the outer diameter: The lathe turns the outermost layer of copper material of the semi-finished product into the specified size.

[0011] (c) The inner hook is machined to the predetermined thickness by using an inner hook cutter to machine the position of the subsequent milling claw of the semi-finished product after the outer diameter is machined;

[0012] (c) Milling: Place the product on a milling machine and cut grooves between the blades of the commutator by moving the insert up and down. For example... Figure 1 As shown in (d).

[0013] (d) Milling the claws: The cutting tools mill the claw shape onto the upper end of the product. For example... Figure 1 As shown in (e).

[0014] (e) Hook bending: Place the product into the mold and bend the claw formed in step (c) into the specified shape. For example... Figure 1 As shown in (f).

[0015] (f) Test for leakage current: Place the sample inside the mold and apply electricity to check if there is any leakage between the copper sheets. If no electricity is applied, the sample is qualified; if electricity is applied, the sample is unqualified.

[0016] (6) Check whether the appearance is qualified, and then pack and ship.

[0017] The entire manufacturing process requires more than ten steps, with milling the claws and slots taking a considerable amount of time, the time being directly proportional to the number of copper sheets. With increasing product competition and rising labor costs, companies urgently need to further develop their processes to reduce production costs and enhance market competitiveness. Summary of the Invention

[0018] The primary objective of this invention is to address the shortcomings of the prior art by providing a novel and ingeniously designed copper sheet for a micro-motor commutator that reduces the number of commutator manufacturing steps.

[0019] The latter objective of this invention is to provide a fabrication process for a micro motor commutator based on the aforementioned copper sheet.

[0020] The preceding technical solution of the present invention is implemented as follows: a copper sheet for a micro motor commutator includes a long strip-shaped body, one end of which is integrally formed with a claw portion, the width w1 of which is smaller than the width w2 of the body.

[0021] In the aforementioned copper sheet for a micro motor commutator, the claw portion is located in the middle of one end of the body, and clearance notches are formed on both sides of the claw portion.

[0022] In the copper sheet for a micro motor commutator described above, a positioning part is integrally formed on the inner side of the body along the length direction.

[0023] In the copper sheet for a micro motor commutator described above, a transition portion is integrally formed between the body and the claw portion, and the width w3 of the transition portion is between the width w1 of the claw portion and the width w2 of the body.

[0024] By adopting the above structure, the present invention can save the subsequent process of milling the claw on the copper sheet by integrally forming the claw at one end of the body, compared with the prior art, thus further simplifying the manufacturing process, effectively reducing production costs, shortening the production cycle, and improving production efficiency.

[0025] The latter technical solution of the present invention is achieved as follows: a fabrication process for a micro motor commutator includes the following steps:

[0026] (1) Stamping: The raw copper wire is stamped into a single copper sheet by using a die and a punch press;

[0027] (2) Arrange the copper sheets in a circular pattern by inserting them into the rubber sleeve;

[0028] (3) Injection molding: Press the rings arranged in step (2) into the injection molding machine mold, and injection mold them into the mold to form a commutator semi-finished product;

[0029] (4) Curing: The commutator semi-finished product is cured by high-temperature baking for 15-25 hours;

[0030] (5) Finishing;

[0031] (6) Inspect the appearance for compliance and pack and ship the goods;

[0032] Wherein, the copper sheet in step (1) is the copper sheet of claim 1;

[0033] The finishing process described in step (5) specifically includes: (a) turning the inner hole; (b) turning the outer circle; (c) milling the groove; (d) bending the hook; and (e) leakage current testing.

[0034] In the above-mentioned method for preparing a micro motor commutator, step (2) specifically involves arranging individual copper sheets into a ring using a freeing device and then inserting them into a rubber sleeve to fix them into a circular ring.

[0035] More preferably, in step (2), when the copper sheet is inserted into the rubber sleeve, the claws are exposed outside the rubber sleeve.

[0036] Compared with the prior art, the present invention, after adopting the above-described process, has the following beneficial effects:

[0037] (1) By pre-forming the claw part during the copper sheet stamping process, the milling claw process and corresponding milling claw equipment during finishing are eliminated, which not only improves production efficiency but also saves equipment costs. According to calculations, saving the milling claw process saves about 15% of the cost of finishing. The effect is significant.

[0038] (2) The claw is formed by stamping. Compared with the claw formed by precision milling, there will be no edge defects such as burrs and flash, which helps to improve product quality and stability. At the same time, the thickness of the stamped claw is also predetermined according to the requirements. There is no need to make an internal hook later. The corresponding internal hook station and related equipment and tooling can be eliminated. According to calculations, saving the internal hook process can save about 10% of the cost of precision machining.

[0039] (3) Since the copper sheet is pre-stamped with claws, the height of the rubber sleeve can be reduced by about 50% when the sheets are arranged, the cost of the rubber sleeve is reduced, and thus the production cost of the product is also reduced. Attached Figure Description

[0040] The present invention will be further described in detail below with reference to the embodiments shown in the accompanying drawings, but this does not constitute any limitation on the present invention.

[0041] Figure 1 This is a schematic diagram of the manufacturing process of a traditional commutator;

[0042] Figure 2 This is a three-dimensional structural diagram of the copper sheet of the present invention;

[0043] Figure 3 This is a schematic diagram of the orthographic projection of the copper sheet of the present invention;

[0044] Figure 4 This is a schematic diagram of the manufacturing process of the commutator of the present invention.

[0045] In the diagram: 1. Body; 2. Claw; 3. Relief notch; 4. Positioning part; 5. Transition part. Detailed Implementation

[0046] See Figure 2 and Figure 3 As shown, a copper sheet for a micro motor commutator according to the present invention includes a long strip-shaped body 1, one end of which is integrally formed with a claw portion 2, the width w1 of which is smaller than the width w2 of the body 1. The claw portion is cleverly integrally formed during the stamping of the copper sheet, eliminating the need for subsequent milling and the corresponding milling equipment during finishing, thus improving production efficiency and reducing production costs.

[0047] More preferably, the claw portion 2 is located at the middle of one end of the body 1, and clearance notches 3 are formed on both sides of the claw portion 2. The clearance notches between adjacent claw portions are the gaps created by milling grooves and claws during subsequent finishing. The size of the clearance notches depends on the requirements of different products.

[0048] More preferably, a positioning part 4 is integrally formed on the inner side of the body 1 along the length direction. The positioning part is used to effectively integrate with the insulator during subsequent injection molding, ensuring the stability of the body and preventing the body from shifting or falling off.

[0049] More preferably, a transition portion 5 is integrally formed between the body 1 and the claw portion 2, and the width w3 of the transition portion 5 is between the width w1 of the claw portion 2 and the width w2 of the body 1. The position corresponding to the transition portion is the notch position formed during the stamping of copper sheets in the prior art. Its function is that when two adjacent copper sheets are mated, the two opposite notches fit together to form a positioning window, which facilitates the positioning of the hook groove position during milling in the finishing process.

[0050] See Figure 4 As shown, the fabrication process of a micro motor commutator according to the present invention includes the following steps:

[0051] (1) Stamping: The raw copper wire is stamped into a single copper sheet using a die and a punch press; the copper sheet is the copper sheet described above.

[0052] (2) Arrange the individual copper sheets into a ring using a free-form device and then insert them into the rubber sleeve to fix them into a circular shape. During the arrangement, when the copper sheets are inserted into the rubber sleeve, the claws face outwards and protrude outside the rubber sleeve. This can reduce the height of the rubber sleeve, reduce the input of rubber sleeve materials, and reduce the cost of using the rubber sleeve.

[0053] (3) Injection molding: Press the rings arranged in step (2) into the injection molding machine mold, and injection mold them into the mold to form a commutator semi-finished product;

[0054] (4) Curing: The commutator semi-finished product is cured by high-temperature baking for 15-25 hours;

[0055] (5) Finishing; the finishing specifically includes: (a) turning the inner hole; (b) turning the outer circle; (c) milling the groove; (d) bending the hook; (e) leakage test.

[0056] The claws that are machined during finishing are pre-formed during copper sheet stamping, thus saving the milling process and significantly improving the production speed. Moreover, the reduction in processes also effectively reduces production costs.

[0057] The above-described embodiments are preferred embodiments of the present invention and are only used to facilitate the illustration of the present invention. They are not intended to limit the present invention in any way. Any person skilled in the art who makes local modifications or alterations to the technical content disclosed in the present invention without departing from the scope of the technical features of the present invention shall still fall within the scope of the technical features of the present invention.

Claims

1. A copper strip for a micro motor commutator, comprising a strip-shaped body (1), characterized in that, One end of the body (1) is integrally formed with a claw (2), and the width w1 of the claw (2) is smaller than the width w2 of the body (1).

2. The copper sheet for a micro-motor commutator according to claim 1, characterized in that, The claw (2) is located in the middle of one end of the body (1), and clearance notches (3) are formed on both sides of the claw (2).

3. The copper sheet for a micro-motor commutator according to claim 1, characterized in that, The inner side of the main body (1) is integrally formed with a positioning part (4) along the length direction.

4. The copper sheet for a micro-motor commutator according to claim 1, characterized in that, A transition portion (5) is integrally formed between the body (1) and the claw portion (2), and the width w3 of the transition portion (5) is between the width w1 of the claw portion (2) and the width w2 of the body (1).

5. A fabrication process for a micro-motor commutator, comprising the following steps: (1) Stamping: The raw copper wire is stamped into a single copper sheet by using a die and a punch press; (2) Arrange the copper sheets in a circular pattern by inserting them into the rubber sleeve; (3) Injection molding: Press the rings arranged in step (2) into the injection molding machine mold, and injection mold them into the mold to form a commutator semi-finished product; (4) Curing: The commutator semi-finished product is cured by high-temperature baking for 15-25 hours; (5) Finishing; (6) Inspect the appearance for compliance and pack and ship the goods; Its features are, The copper sheet mentioned in step (1) is the copper sheet described in claim 1; The finishing process described in step (5) specifically includes: (a) turning the inner hole; (b) turning the outer circle; (c) milling the groove; (d) bending the hook; and (e) leakage current testing.

6. The method for fabricating a micro-motor commutator according to claim 5, characterized in that, Step (2) specifically involves arranging individual copper sheets into a ring using a free-form device, then inserting them into a rubber sleeve and fixing them into a circular ring.

7. The method for fabricating a micro-motor commutator according to claim 5, characterized in that, In step (2), when the copper sheet is inserted into the rubber sleeve, the claws are exposed outside the rubber sleeve.

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