Rotor assembly of automobile starter

Abstract

The utility model discloses an automobile starter rotor assembly, and belongs to the technical field of automobile starters. The motor comprises a rotor assembly, a commutator is pressed at one end of a central shaft of the rotor assembly, a wire fixing gasket is arranged on the central shaft of the rotor assembly and between the rotor assembly and the commutator, a plurality of wire embedding grooves are uniformly distributed on the circumference of the outer edge of the wire fixing gasket, and the wire fixing gasket and the circumference of the opposite end of the commutator are positioned and inserted. The wire embedding grooves are in one-to-one correspondence with wire welding grooves of the commutator; and inner and outer winding wire ends of the rotor assembly respectively penetrate through the corresponding wire embedding grooves and then are welded in the corresponding wire welding grooves. The beneficial effects are that inner and outer layer winding wire ends to be welded are aligned and embedded into the wire embedding grooves of the wire fixing gaskets, so that the winding wire ends can be consistent with the wire welding grooves of the commutator without the lifting table in position; according to the utility model, the brazing solder can be placed more accurately, the pressure applied by the main welding electrode does not cause offset and dislocation of a wire end during power-on welding, the welding quality is ensured, and the first-pass yield of welding is greatly improved.

Description

Technical Field

[0001] This utility model relates to the field of automotive starter technology, and in particular to an automotive starter rotor assembly. Background Technology

[0002] Currently, the connection between the rotor windings and commutator of automotive starter motors is achieved using brazing. This brazing process utilizes a commutator without a riser platform, which, compared to the riser platform commutator used in conventional pressure welding, eliminates the riser platform design, significantly reducing the amount of copper used and saving material costs. However, because the winding slots in the riser-less commutator are very short, they can only wrap around half of the inner winding wire ends, while the outer winding wire ends are completely outside the winding slots, lacking a reliable method for securing the winding wire ends. This situation can cause the following problems:

[0003] 1. After the winding is twisted, the outer winding wire ends and the inner winding wire ends may not be on the same straight line. When the welding main welding electrode contacts the base material, i.e. the outer winding wire ends, the pressure applied will cause the outer and inner winding wire ends to be misaligned.

[0004] 2. When the outer and inner winding wire ends are misaligned, once energized, the main welding electrode is heated and under pressure, which increases the misalignment and deformation of the winding wire ends, causing uneven melting of the brazing solder, resulting in weak welding between the inner and outer layers, and thus causing poor welding and reducing the first-pass yield of brazing. Utility Model Content

[0005] The technical problem to be solved by this utility model is to provide an automotive starter rotor assembly that can ensure that the winding wire ends are aligned with the welding slots of the commutator, thereby improving the first-pass yield of brazing and the quality of rotor welding.

[0006] The technical solution of this utility model is as follows:

[0007] A rotor assembly for an automotive starter includes a rotor assembly with a commutator press-fitted at one end of the central shaft of the rotor assembly. The key feature is that a wire-fixing washer is provided on the central shaft of the rotor assembly between the rotor assembly and the commutator. Multiple wire-inserting grooves are evenly distributed around the outer circumference of the wire-fixing washer. The wire-fixing washer is positioned and inserted into the opposite circumference of the commutator, so that the wire-inserting grooves correspond one-to-one with the welding grooves of the commutator. The inner and outer winding wire ends of the rotor assembly pass through the corresponding wire-inserting grooves and are then welded into the corresponding welding grooves.

[0008] As a further preferred embodiment, one end of the commutator-corresponding fixing pad is truncated cone-shaped, the central hole of the fixing pad is stepped, and the large hole at one end of the commutator is tapered, which matches the taper of the truncated cone.

[0009] As a further preferred embodiment, the commutator has multiple positioning holes evenly distributed around one end of the fixed wire pad, and multiple positioning pins evenly distributed around the circumference on the stepped surface inside the central hole of the fixed wire pad. The positioning pins are inserted into the positioning holes one by one to achieve circumferential positioning of the fixed wire pad and the commutator.

[0010] As a further preferred option, the fixing pad is made of nylon or Teflon material and is formed by one injection molding process.

[0011] As a further preferred embodiment, the commutator includes a metal bushing, an insulating sleeve, and multiple commutator segments evenly distributed around the outer edge of the insulating sleeve. The insulating sleeve is formed by heating and pressing bakelite powder using a compression molding machine. A mica sheet is provided between two adjacent commutator segments. Annular grooves are provided at both ends of the multiple commutator segments, and fastening rings are embedded in the annular grooves to ensure the tight assembly of the commutator segments and improve the overspeed test requirements of the finished commutator.

[0012] The beneficial effects of this utility model are:

[0013] Because a wire-fixing shim is provided on the central shaft of the rotor assembly between the rotor assembly and the commutator, and the wire slots on the wire-fixing shim correspond one-to-one with the welding slots of the commutator, the inner and outer winding wire ends to be welded can be aligned and embedded into the wire slots of the wire-fixing shim during the manufacturing process. This ensures that the winding wire ends are in the same position as the welding slots of the commutator without a riser. This allows for more accurate placement of the brazing solder, and the pressure applied by the main welding electrode during welding will not cause the wire ends to shift or misalign, thus ensuring welding quality and greatly improving the first-pass yield. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of this utility model.

[0015] Figure 2 yes Figure 1 Top view.

[0016] Figure 3 This is a schematic diagram of the structure of the commutator and rotor assembly after the commutator is press-fitted with a fixed-line gasket.

[0017] Figure 4 This is an exploded view of the present invention.

[0018] Figure 5 This is a schematic diagram of the structure of the wire-fixing gasket.

[0019] In the diagram: 1. Rotor assembly; 2. Winding wire end; 3. Commutator; 4. Wire fixing gasket; 401. Wire groove; 402. Positioning pin; 5. Metal bushing; 6. Insulating sleeve; 601. Positioning hole; 7. Commutator segment; 8. Fastening ring; 9. Mica sheet. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0021] like Figures 1-5 As shown, this utility model relates to an automotive starter rotor assembly, including a rotor assembly 1. A commutator 3 is press-fitted onto one end of the central shaft of the rotor assembly 1. A wire-fixing pad 4 is clamped between the rotor assembly 1 and the commutator 3 on the central shaft of the rotor assembly 1. Multiple wire-inserting grooves 401 are evenly distributed on the outer circumference of the wire-fixing pad 4. The wire-fixing pad 4 is circumferentially positioned and inserted into the opposite end of the commutator 3, so that the wire-inserting grooves 401 correspond one-to-one with the welding grooves of the commutator 3. The inner and outer winding wire ends 2 of the rotor assembly 1 pass through the corresponding wire-inserting grooves 401 and are welded to the corresponding welding grooves on the commutator 3.

[0022] The commutator 3 has a truncated cone shape at one end corresponding to the wire fixing pad 4. The wire fixing pad 4 is made of nylon or Teflon material and is formed by one-time injection molding. The center hole of the wire fixing pad 4 is stepped, and the large hole at one end of the commutator 3 is tapered, which matches the taper of the truncated cone.

[0023] The commutator 3 has multiple positioning holes 601 evenly distributed around one end of the fixed pad 4. In this embodiment, three positioning holes are used as an example. Multiple positioning pins 402 are evenly distributed around the circumference of the stepped surface inside the central hole of the fixed pad 4. The positioning pins 402 are inserted into the positioning holes 601 one by one to realize the circumferential positioning of the fixed pad 4 and the commutator 3.

[0024] The commutator 3 includes a metal bushing 5, an insulating sleeve 6, and multiple commutator segments 7 arranged circumferentially around the outer edge of the insulating sleeve 6, nested from the inside out. The insulating sleeve 6 is formed by heating and pressing bakelite powder using a compression molding machine. The positioning hole 601 is located at one end of the insulating sleeve 6. A mica sheet 9 is sandwiched between two adjacent commutator segments 7. A wire bonding groove is provided at the outer edge of each commutator segment 7 near the wire fixing pad 4. Annular grooves are provided at both ends of the multiple commutator segments 7, and fastening rings 8 are embedded in the annular grooves to ensure the tight assembly of the commutator segments 7 and improve the overspeed test requirements of the finished commutator 3.

[0025] During manufacturing, after completing the pressing, paper insertion, wire insertion, and toggle processes of the central shaft of rotor assembly 1, in the pressing process of commutator 3, commutator 3 and wire-fixing washer 4 are aligned with the wire-insertion groove 401 and the wire-welding groove of commutator 3, and the positioning pin 402 is inserted into the positioning hole 601 to form a whole. Then, commutator 3 and wire-fixing washer 4 are pressed together onto the central shaft of rotor assembly 1. The schematic diagram after pressing is shown below. Figure 3 As shown. Then, the process proceeds to the slotting process, where all inner and outer windings 2 are simultaneously pushed into the slots 401 of the wire-fixing pads 4 using the slotting equipment; so that all windings of the rotor assembly 1 are embedded into their respective welding slots corresponding to the commutator 3 at the required angles, thus preparing for brazing.

[0026] The solder is then placed between the two winding ends 2 and between the inner winding end and the soldering slot of the commutator 3. The solder is then applied to the working surface of the commutator 3 via the auxiliary solder electrode, while the main solder electrode contacts the outer winding end. Pressure is applied to the main solder electrode, and it is heated by electricity. Current flows from the main solder electrode to the auxiliary solder electrode, heating this area and melting the solder, thus achieving brazing. The wire-fixing shim 4 prevents the winding ends from shifting or misaligning, ensuring welding quality and significantly improving the first-pass yield.

[0027] Although the embodiments of this utility model have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for this utility model. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, this utility model is not limited to the specific details and the illustrations shown and described herein.

Claims

1. A starter rotor assembly for an automobile, comprising a rotor assembly, a commutator being press fitted at one end of the central shaft of the rotor assembly, characterized in that The center shaft of the rotor assembly is provided with a wire fixing pad between the rotor assembly and the commutator, a plurality of wire embedding grooves are uniformly distributed on the outer edge of the wire fixing pad, the wire fixing pad is circularly positioned and inserted with the opposite end of the commutator, so that the wire embedding grooves correspond to the wire welding grooves of the commutator one by one; the wire heads of the inner and outer layer windings of the rotor assembly are respectively welded in the corresponding wire welding grooves after passing through the corresponding wire embedding grooves.

2. A starter rotor assembly for an automotive vehicle as set forth in claim 1 wherein: The end of the commutator corresponding to the wire fixing pad is in the shape of a conical platform, the center hole of the wire fixing pad is in the shape of a step, the large hole of the end of the commutator corresponding to the wire fixing pad is in the shape of a taper hole, and the taper of the taper hole and the taper of the conical platform are matched with each other.

3. A starter rotor assembly for an automotive vehicle as set forth in claim 2 wherein: The end of the commutator corresponding to the wire fixing pad is uniformly provided with a plurality of positioning holes, and a plurality of positioning pins are uniformly distributed on the step surface in the center hole of the wire fixing pad, the positioning pins and the positioning holes are one by one inserted to realize the circular positioning of the wire fixing pad and the commutator.

4. A starter rotor assembly for an automotive vehicle as set forth in any of claims 1-3, characterized by: The wire fixing pad is made of nylon or Teflon material by one injection molding.

5. A starter rotor assembly for an automotive vehicle as set forth in any of claims 1-3, characterized by: The commutator comprises a metal bushing, an insulating sleeve and a plurality of commutator sheets uniformly distributed on the outer edge of the insulating sleeve, the insulating sleeve is formed by heating and pressing of bakelite powder by a pressing machine, a mica sheet is arranged between two adjacent commutator sheets, annular grooves are arranged at both ends of the plurality of commutator sheets and fastening rings are respectively embedded in the annular grooves to ensure the fastening assembly of the commutator sheets and improve the overspeed test requirement of the commutator product.

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