Wear-resistant commutator
By setting bevel and arc surface on the commutator's commutator's commutator, and using spring blades and auxiliary resistance components, the wear and breakage problems of carbon brushes and commutator plates are solved, achieving a longer service life and more stable operation.
Patent Information
- Application Number
- CN202421469716.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-25
- Publication Date
- 2025-04-18
- Estimated Expiration
- 2034-06-25
AI Technical Summary
During the operation of the commutator, the contact between the carbon brush and the commutation plate will lead to wear and carbon powder, affecting the normal operation of the motor and the service life of the carbon brush.
A wear-resistant commutator is designed to avoid breaking contact and scratching between the carbon brush and the commutator sheet by setting bevels and arc surfaces on the commutator sheet, and using spring sheets and auxiliary resistance components, thereby reducing wear.
With this design, the wear of the carbon brush and commutator is significantly reduced, the service life is extended, and the permanent deformation of the spring due to high temperatures is avoided.
Smart Images
Figure CN222775759U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of commutators, in particular to a wear-resistant commutator. Background Art
[0002] The commutator, also known as the rectifier, is an important component on the armature of a DC motor and an AC commutator motor. It is mainly composed of many copper sheets separated by mica sheets, forming a cylindrical or disc-shaped structure. Each copper sheet is connected to several armature winding elements. When the motor is working, the copper sheets will successively contact the fixed brushes when the armature rotates. In a DC motor, the main function of the commutator is to convert the AC in the armature winding into DC between the brushes through the brushes. In an AC commutator motor, the commutator is responsible for making the frequency of the AC between the brushes meet the working requirements.
[0003] In actual application, in order to achieve smooth flow of current, it is usually necessary to ensure a certain contact pressure between the carbon brush and the commutator segment during design to reduce contact resistance and improve the efficiency of power transmission. However, when the motor is commutating, the carbon brush needs to gradually move from the edge of the commutator segment to the central part. In this process, the carbon brush will inevitably come into contact with the edge of the commutator segment. Since the commutator segment is usually made of metal (such as copper), there may be sharp corners at the edge. When these corners come into contact with the carbon brush, they will produce a scratching effect on the surface of the carbon brush. This scratching will not only cause the material on the surface of the carbon brush to be gradually worn away, shortening the service life of the carbon brush, but more seriously, it will also produce a large amount of carbon powder. These carbon powders are tiny particles that are peeled off from the carbon brush material during the scratching process. On the one hand, it will aggravate the wear of the commutator segment. On the other hand, the carbon powder will diffuse inside the motor, posing a threat to the normal operation of the motor, which needs to be improved urgently. Utility Model Content
[0004] The purpose of the utility model is to provide a wear-resistant commutator to solve the problems raised in the above background technology.
[0005] In order to solve the above technical problems, the technical solution adopted by the utility model is:
[0006] A wear-resistant commutator comprises a commutator body, a plurality of commutator segments are arranged equidistantly around the circumference of the commutator body, one end of the commutator segment is bent with a hook, and the end of the hook away from the commutator segment is bent with a blade; both ends of the convex surface of the commutator segment are provided with bevels, and the bevel and the commutator segment are provided with a smooth arc surface at the central position; two grooves are symmetrically provided on one side of the convex surface of the commutator segment, and spring sheets are symmetrically provided at both ends of the convex surface of the commutator segment, and the spring sheets cover the grooves, and auxiliary resistance components are provided inside the grooves, and the auxiliary resistance components are used to provide auxiliary support for the spring sheets; the spring sheets include a supporting base layer arranged in the innermost part, a heat insulation layer is arranged on the outer side of the supporting base layer, a conductive layer is arranged on the side of the heat insulation layer away from the supporting base layer, and a wear-resistant layer is plated on the outer side of the conductive layer.
[0007] By adopting the above technical solution, by setting an oblique angle and an arc surface on the commutator segment, the carbon brush can transition through a relatively smoother process when it starts to contact the commutator segment, and by setting a spring sheet, it is possible to avoid the situation where the carbon brush and the commutator segment are disconnected due to the oblique angle. The spring sheet has a smooth surface and is elastic, which can make the carbon brush contact more smoothly and flexibly, thereby greatly reducing the scratches on the carbon brush during operation, thereby greatly reducing the wear of the commutator and the carbon brush, and increasing the service life of the commutator.
[0008] A further improvement of the technical solution of the utility model is that the auxiliary resistance component includes a sliding rod, which is fixedly connected between the inner walls of the groove, a sliding block is slidably connected to the outer side of the sliding rod, a clamping spring is sleeved on the outer side of the sliding rod, a support rod is hinged on one side of the sliding block, and the end of the support rod away from the sliding block is hinged to the spring sheet.
[0009] By adopting the above technical solution, during the continuous operation of the motor, a large amount of heat will be generated due to the continuous friction between the carbon brush and the commutator plate and the spring plate, thereby making the toughness of the spring plate stronger, but the rebound force weakened. At this time, the clamping spring will provide the main support when the carbon brush passes by. After the spring plate is compressed, it is easy to produce permanent deformation under high temperature. At this time, the spring plate will push the support rod to push the slider to slide, squeezing the clamping spring, and after the carbon brush leaves, the clamping spring rebounds and pushes the slider to reset, and then pushes the spring plate to reset through the support rod, avoiding the situation where the spring plate undergoes permanent deformation due to high temperature under long-term working conditions.
[0010] A further improvement of the technical solution of the utility model is that the spring sheet is rotatably connected to the commutator sheet via a rotating shaft, and the other end of the spring sheet is tightly fitted to the commutator sheet.
[0011] By adopting the above technical solution, the spring sheet slides relative to the rotating shaft under pressure to move; under high temperature conditions, the copper shaft expands slightly, making it fit tightly with the spring sheet and unable to slide easily. As a result, both ends of the spring sheet are fixedly connected to the commutator sheet to a certain extent, so that the deformation of the spring sheet is completely driven by its own deformation (at this time, the toughness is high). When the temperature environment is low, the spring sheet can slide relative to the rotating shaft, thereby alleviating its deformation pressure.
[0012] A further improvement of the technical solution of the utility model is that the material of the supporting base layer is spring steel.
[0013] By adopting the above technical solution, spring steel is set as the supporting body to support and maintain the shape, ensuring that the spring sheet is not easily deformed under high-frequency vibration.
[0014] A further improvement of the technical solution of the utility model is that the heat insulation layer is arranged as a silicon carbide coating.
[0015] By adopting the above technical solution, the silicon carbide coating has high temperature tolerance and corrosion resistance, and at the same time has good toughness, and can be used for thermal insulation of spring leaves.
[0016] A further improvement of the technical solution of the utility model is that the conductive layer is arranged as a mesh structure made of copper wires.
[0017] By adopting the above technical solution, the mesh structure can provide better elasticity and conductivity, while the continuous layered structure has higher strength and stability.
[0018] A further improvement of the technical solution of the utility model is that the wear-resistant layer is set to tungsten carbide material.
[0019] By adopting the above technical solution, the tungsten carbide material can effectively resist wear under high-frequency vibration and extend the service life of the spring leaf.
[0020] Due to the adoption of the above technical solution, the utility model has achieved the following technical progress compared with the prior art:
[0021] 1. The utility model provides a wear-resistant commutator. By setting an oblique angle and an arc surface on the commutator segment, the carbon brush can transition through a relatively smoother process when it starts to contact the commutator segment. A spring sheet is provided to avoid the situation where the carbon brush and the commutator segment are disconnected due to the oblique angle. The spring sheet has a smooth surface and is elastic, so that the carbon brush can contact more smoothly and flexibly, thereby greatly reducing the scratching of the carbon brush during operation, thereby greatly reducing the wear of the commutator and the carbon brush, and increasing the service life of the commutator, which is beneficial to practical applications.
[0022] 2. The utility model provides a wear-resistant commutator. By setting an auxiliary resistance component, a large amount of heat will be generated during the continuous operation of the motor due to the continuous friction between the carbon brush and the commutator plate and the spring plate, thereby making the toughness of the spring plate stronger, but the rebound force weakened. At this time, the holding spring will provide the main support when the carbon brush passes by. After the spring plate is compressed, it is easy to produce permanent deformation under high temperature. At this time, the spring plate will push the support rod to push the slider to slide, squeeze the holding spring, and after the carbon brush leaves, the holding spring rebounds and pushes the slider to reset, and then pushes the spring plate to reset through the support rod, avoiding the situation where the spring plate is permanently deformed due to high temperature under long-term working conditions.
[0023] 3. The utility model provides a wear-resistant commutator, in which a spring sheet is connected to the commutator sheet through a rotating shaft. Under normal conditions, the spring sheet slides relative to the rotating shaft under pressure to move; under high temperature conditions, the copper shaft expands slightly, so that it fits tightly with the spring sheet and cannot slide easily. As a result, both ends of the spring sheet are fixedly connected to the commutator sheet to a certain extent, so that the deformation of the spring sheet is completely driven by its own deformation (at this time, the toughness is high). When the temperature environment is low, the spring sheet can slide relative to the rotating shaft, thereby alleviating its deformation pressure. BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The utility model will be further described below in conjunction with the accompanying drawings.
[0025] Figure 1 It is a structural schematic diagram of the utility model from the first perspective;
[0026] Figure 2 It is a structural schematic diagram of the utility model from a second viewing angle;
[0027] Figure 3 It is a schematic diagram of the overall structure of the commutator segment of the utility model;
[0028] Figure 4 It is a partial cross-sectional structural schematic diagram of the commutator segment of the utility model;
[0029] Figure 5 It is a structural schematic diagram of the spring sheet of the utility model;
[0030] Figure 6 For this utility model Figure 4 Enlarged view of point A in the middle;
[0031] Figure 7 For this utility model Figure 5 Enlarged view of point B in the middle.
[0032] In the figure: 1, commutator body; 21, bevel; 22, arc surface; 3, groove; 4, spring sheet; 41, supporting base layer; 42, heat insulation layer; 43, conductive layer; 44, wear-resistant layer; 5, sliding rod; 6, slider; 7, tightening spring; 8, support rod; 9, hook; 10, blade. DETAILED DESCRIPTION
[0033] The present invention is further described in detail below in conjunction with the embodiments:
[0034] Example 1
[0035] like Figure 1-Figure 7 As shown, the utility model provides a wear-resistant commutator, including a commutator body 1, a plurality of commutator segments are equidistantly arranged around the circumference of the commutator body 1, one end of the commutator segment is bent with a hook 9, and the end of the hook 9 away from the commutator segment is bent with a blade 10; both ends of the convex surface of the commutator segment are provided with bevels 21, and the bevel 21 and the commutator segment are provided with a smooth arc surface 22 at the central position, two grooves 3 are symmetrically provided on one side of the convex surface of the commutator segment, and spring sheets 4 are symmetrically arranged at both ends of the convex surface of the commutator segment, the spring sheets 4 cover the grooves 3, and auxiliary resistance components are arranged inside the grooves 3, and the auxiliary resistance components are used to provide auxiliary support for the spring sheets 4; the spring sheets 4 include a supporting base layer 41 arranged in the innermost part, a heat insulation layer 42 is arranged on the outer side of the supporting base layer 41, a conductive layer 43 is arranged on the side of the heat insulation layer 42 away from the supporting base layer 41, and a wear-resistant layer 44 is plated on the outer side of the conductive layer 43.
[0036] In this embodiment, by setting an oblique angle 21 and an arc surface 22 on the commutator segment, the carbon brush can transition through a relatively smoother process when it starts to contact the commutator segment, and the spring sheet 4 is provided to avoid the situation where the carbon brush and the commutator segment are disconnected due to the oblique angle 21. The spring sheet 4 has a smooth surface and is elastic, which can make the carbon brush contact more smoothly and flexibly, thereby greatly reducing the scratches on the carbon brush during operation, thereby greatly reducing the wear of the commutator and the carbon brush, and increasing the service life of the commutator, which is beneficial to practical applications.
[0037] Example 2
[0038] like Figure 4 and Figure 6 As shown, on the basis of Example 1, the utility model provides a technical solution: preferably, the auxiliary resistance component includes a slide rod 5, the slide rod 5 is fixedly connected between the inner walls of the groove 3, the outer side of the slide rod 5 is slidably connected with a slider 6, the outer side of the slide rod 5 is sleeved with a clamping spring 7, one side of the slider 6 is hinged with a support rod 8, and the end of the support rod 8 away from the slider 6 is hinged to the spring sheet 4.
[0039] In this embodiment, during the continuous operation of the motor, a large amount of heat will be generated due to the continuous friction between the carbon brush and the commutator plate and the spring plate 4, thereby making the toughness of the spring plate 4 stronger, but the resilience weakened. At this time, the clamping spring 7 will provide the main support when the carbon brush passes by. After the spring plate 4 is compressed, it is easy to produce permanent deformation under high temperature. At this time, the spring plate 4 will push the support rod 8 to push the slider 6 to slide, squeezing the clamping spring 7, and after the carbon brush leaves, the clamping spring 7 rebounds and pushes the slider 6 to reset, and then pushes the spring plate 4 to reset through the support rod 8, thereby avoiding the permanent deformation of the spring plate 4 due to high temperature under long-term working conditions.
[0040] like Figure 3 and Figure 4 As shown, preferably, the spring sheet 4 is rotatably connected to the commutator segment via a rotating shaft, and the other end of the spring sheet 4 is tightly fitted to the commutator segment.
[0041] In this embodiment, the rotating shaft connecting the spring piece 4 and the commutator piece is a copper shaft. Under normal conditions, the spring piece 4 slides relative to the rotating shaft under pressure to move; under high temperature conditions, the copper shaft expands slightly, making it fit tightly with the spring piece 4 and unable to slide easily. As a result, both ends of the spring piece 4 are fixedly connected to the commutator piece to a certain extent, so that the deformation of the spring piece 4 is completely driven by its own deformation (at this time, the toughness is high). When the temperature environment is low, the spring piece 4 can slide relative to the rotating shaft, thereby alleviating its deformation pressure.
[0042] Preferably, the support base 41 is made of spring steel.
[0043] In this embodiment, spring steel is used as the supporting body to provide support and maintain the shape, thereby ensuring that the spring sheet 4 is not easily deformed under high-frequency vibration.
[0044] Preferably, the heat insulation layer 42 is configured as a silicon carbide coating.
[0045] In this embodiment, the silicon carbide coating has high temperature tolerance and corrosion resistance, and also has good toughness, and can be used for heat insulation of the spring sheet 4 .
[0046] Preferably, the conductive layer 43 is configured as a mesh structure made of copper wires.
[0047] In this embodiment, the mesh structure can provide better elasticity and conductivity, while the continuous layer structure has higher strength and stability.
[0048] Preferably, the wear-resistant layer 44 is made of tungsten carbide material.
[0049] In this embodiment, the tungsten carbide material can effectively resist wear under high-frequency vibration and extend the service life of the spring sheet 4.
[0050] The working principle of the wear-resistant commutator is described in detail below.
[0051] like Figure 1-Figure 7 As shown in the figure, during the operation of the commutator body 1, the commutator segment rotates relative to the axis, and during the process, the carbon brush will first contact the arc surface 22 on the spring sheet 4, and the spring sheet 4 is squeezed and deformed to provide the carbon brush with a relatively smooth pre-contact, and then transition to the outer wall of the commutator segment to avoid the sharp corners from scratching the carbon brush; when the spring sheet 4 is contacted and squeezed by the carbon brush, the middle position of the spring sheet 4 is pressed and abutted against the commutator segment, and the carbon brush and the commutator segment are electrically conductive through the spring sheet 4; the carbon brush can smoothly contact the commutator segment after passing through the spring sheet 4, thereby avoiding the situation where the corner position scratches the carbon brush; during the continuous operation of the motor, due to the contact between the carbon brush and the commutator segment and the spring sheet 4, the carbon brush is The spring leaf 4 is in continuous friction, so a large amount of heat is generated, which makes the toughness of the spring leaf 4 stronger, but the resilience is weakened. At this time, the pressing spring 7 provides the main support when the carbon brush passes by. After the spring leaf 4 is compressed, it is easy to produce permanent deformation under high temperature. At this time, the spring leaf 4 will push the support rod 8 to push the slider 6 to slide, squeeze the pressing spring 7, and after the carbon brush leaves, the pressing spring 7 rebounds and pushes the slider 6 to reset, and then pushes the spring leaf 4 to reset through the support rod 8, avoiding the permanent deformation of the spring leaf 4 due to high temperature under long-term working conditions, thereby greatly reducing the wear of the commutator and the carbon brush, and increasing the service life of the commutator, which is beneficial to practical applications.
[0052] The contacting portion between the spring piece 4 and the commutator segment does not contact the carbon brush.
[0053] The above generally describes the present invention in detail, but it is obvious to a person skilled in the art that some modifications or improvements can be made to the present invention. Therefore, modifications or improvements that do not deviate from the spirit of the present invention are within the scope of protection of the present invention.
Claims
1. A wear-resistant commutator, comprising a commutator body (1), wherein a plurality of commutator segments are equidistantly arranged around the commutator body (1) in the circumferential direction, wherein one end of the commutator segment is bent with a hook (9), and the end of the hook (9) away from the commutator segment is bent with a blade (10); characterized in that: Both ends of one side of the convex surface of the commutator segment are provided with bevels (21), and a smooth arc surface (22) is provided between the bevels (21) and the central position of the commutator segment. Two grooves (3) are symmetrically provided on one side of the convex surface of the commutator segment. Spring sheets (4) are symmetrically provided at both ends of the convex surface of the commutator segment. The spring sheets (4) cover the grooves (3). An auxiliary abutment component is provided inside the grooves (3). The auxiliary abutment component is used to provide auxiliary support for the spring sheets (4). The spring sheet (4) comprises a supporting base layer (41) arranged at the innermost part, a heat insulating layer (42) is arranged on the outer side of the supporting base layer (41), a conductive layer (43) is arranged on the side of the heat insulating layer (42) away from the supporting base layer (41), and a wear-resistant layer (44) is plated on the outer side of the conductive layer (43).
2. A wear-resistant commutator according to claim 1, characterized in that: The auxiliary resistance component comprises a slide rod (5), the slide rod (5) is fixedly connected between the inner walls of the groove (3), the outer side of the slide rod (5) is slidably connected to a slider (6), the outer side of the slide rod (5) is sleeved with a clamping spring (7), one side of the slider (6) is hinged with a support rod (8), and the end of the support rod (8) away from the slider (6) is hinged to the spring sheet (4).
3. A wear-resistant commutator according to claim 2, characterized in that: One end of the spring sheet (4) is rotatably connected to the commutator segment via a rotating shaft, and the other end of the spring sheet (4) is tightly fitted to the commutator segment.
4. A wear-resistant commutator according to claim 3, characterized in that: The material of the supporting base layer (41) is spring steel.
5. A wear-resistant commutator according to claim 4, characterized in that: The heat insulation layer (42) is configured as a silicon carbide coating.
6. A wear-resistant commutator according to claim 5, characterized in that: The conductive layer (43) is configured as a mesh structure made of copper wires.
7. A wear-resistant commutator according to claim 6, characterized in that: The wear-resistant layer (44) is made of tungsten carbide material.