All-plastic commutator
By setting an adhesive layer and filling the gap with the plug in the all-plastic commutator, and using a snap ring to fix the plug, the problems of brush contact wear and abnormal noise caused by processing errors and assembly gaps are solved, and a more stable brush contact structure is achieved.
Patent Information
- Application Number
- CN202520172047.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-24
- Publication Date
- 2026-01-13
- Estimated Expiration
- 2035-01-24
AI Technical Summary
Existing all-plastic commutators suffer from severe wear of brush contacts and abnormal noise during circumferential rotation due to machining errors and assembly gaps.
By placing an adhesive layer between the protrusion of the brush contact and the through hole of the bakelite powder body, and using the insert rod and coaxial through hole to fill the gap, combined with the retaining spring to fix the insert rod, the machining and assembly gaps are eliminated, thereby enhancing the stability of the brush contact.
It effectively fills and eliminates machining and assembly gaps, reduces wear on brush contacts, reduces abnormal noise, and improves the stability and durability of brush contacts.
Smart Images
Figure CN223797700U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of commutator technology, and more specifically to an all-plastic commutator. Background Technology
[0002] An all-plastic commutator is a commutator that includes commutator segments and bakelite powder body, and there is no mica sheet between two adjacent commutator segments as a partition between them.
[0003] There is a type of all-plastic commutator, such as Figure 1 As shown, the device includes a bakelite powder body 90, a plurality of commutator segments 91 arranged in a ring array on the bakelite powder body 90, and a cover plate 92. Each commutator segment assembly 91 includes a winding member 911 and a brush contact member 912. The bottom of the winding member 911 is integrally injection molded with the bakelite powder body 90. The bottom of each brush contact member 912 has a plurality of protrusions 9121, and each protrusion 9121 has a through hole 9122. The body 90 has several grooves 901, and one end of the cover plate 92 has several inserts 93. The protrusions 9121 extend into the grooves 901. After each protrusion 9121 is inserted into its corresponding groove 901, the inserts 93 of the cover plate 92 are inserted into the corresponding through holes 9122 and extend to the other end of the bakelite body 90. The other end of the insert 93 is fixed with a nut, thus fixing the brush contact 912 to the bakelite body 90. However, due to machining errors and assembly gaps between the through holes 9122 and the shaft, the all-plastic commutator experiences slight movement during circumferential rotation due to these gaps, which exacerbates the wear of the brush contact 912 and produces abnormal noise.
[0004] Therefore, there is a need for an all-plastic commutator that can fill and eliminate machining and assembly gaps and provide more stable brush contacts. Utility Model Content
[0005] The main objective of this application is to provide an all-plastic commutator, wherein the all-plastic commutator includes a bakelite powder body, a plurality of commutator segments arranged in a circular array, and a plurality of inserts. The outer wall of the bakelite powder body has a plurality of grooves and a plurality of first through holes, each groove communicating with a corresponding first through hole. Each commutator segment assembly includes a winding component and a brush contact component. The winding component is integrally injection molded with the bakelite powder body. The bottom of the brush contact component has a plurality of protrusions, each of which... Each component has a second through hole, the wall of which has an adhesive layer. Each protrusion extends into the corresponding groove. The first and second through holes are coaxially arranged. One end of the brush contact abuts against the winding component. The insert and the commutator are assembled one-to-one. Each insert is inserted into the corresponding first and second through holes. The gap between the insert and the first and second through holes is filled with adhesive, thereby filling and eliminating processing and assembly gaps and making the brush contact more stable.
[0006] Another objective of this application is to provide an all-plastic commutator, wherein the bakelite powder body further has a countersunk hole and an annular groove, the countersunk hole is located at one end of the bakelite powder body away from the winding member, the annular groove is located between the countersunk hole and each of the first through holes, and the all-plastic commutator further includes a retaining spring, the retaining spring is disposed in the annular groove, and the retaining spring abuts against one end of the insertion rod. By setting the retaining spring to abut against the insertion rod and restrict its axial movement, the axial force at the glue is reduced.
[0007] To achieve at least one of the above-mentioned objectives, this application provides an all-plastic commutator, wherein the all-plastic commutator comprises:
[0008] A bakelite powder body, wherein the outer side wall of the bakelite powder body has a plurality of grooves and a plurality of first through holes, each groove communicating with a corresponding first through hole; and
[0009] A plurality of commutator segments arranged in a circular array, each commutator segment assembly including a winding component and a brush contact component, wherein the winding component is integrally injection molded with the bakelite powder body, the bottom of the brush contact component has a plurality of protrusions, each protrusion having a second through hole, the wall of the second through hole having an adhesive layer, each protrusion extending into a corresponding groove, and the first through hole and the second through hole being coaxially arranged, and one end of the brush contact component abutting against the winding component; and
[0010] A plurality of insert rods are provided, each insert rod corresponding to a commutator segment, and each insert rod is inserted into the corresponding first through hole and second through hole.
[0011] In one or more embodiments of this application, the bakelite powder body further has a countersunk hole and an annular groove. The countersunk hole is located at one end of the bakelite powder body away from the winding member. The annular groove is located between the countersunk hole and each of the first through holes. The all-plastic commutator further includes a retaining spring. The retaining spring is disposed in the annular groove and abuts against one end of the insertion rod.
[0012] In one or more embodiments of this application, the bakelite powder body has a plurality of striking holes at one end away from the countersunk hole. The striking holes extend from the end face of the bakelite powder body away from the countersunk hole to the corresponding second through hole and pass through the winding member.
[0013] In one or more embodiments of this application, each of the winding members has a trapezoidal groove at its bottom.
[0014] In one or more embodiments of this application, the winding member has a winding portion and a pressure receiving portion at each end, and the brush contact member has a pressing portion at one end near the winding member. When the first through hole is directly opposite the second through hole, the pressing portion abuts against the pressure receiving portion.
[0015] In one or more embodiments of this application, the bakelite powder body also has a plurality of anti-short-circuit slots, and each of the two adjacent commutator segments has one of the anti-short-circuit slots.
[0016] In one or more embodiments of this application, the center of the bakelite powder body has a through hole, and the inner radial dimension of the retaining spring is larger than the diameter of the through hole.
[0017] In this embodiment, the all-plastic commutator includes a bakelite powder body, several commutator segments arranged in a ring array, and several insert rods. The outer wall of the bakelite powder body has several grooves and a first through hole. Each groove communicates with the corresponding first through hole. Each commutator segment assembly includes a winding component and a brush contact component. The winding component is integrally injection molded with the bakelite powder body. The bottom of the brush contact component has several protrusions. Each protrusion has a second through hole. The wall of the second through hole has an adhesive layer. Each protrusion extends into the corresponding groove. The first through hole and the second through hole are arranged coaxially. One end of the brush contact component abuts against the winding component. The insert rods correspond one-to-one with the commutator segment assemblies. Each insert rod is inserted into the corresponding first through hole and second through hole. The gap between the insert rod and the first through hole and the second through hole is filled with adhesive, thereby filling and eliminating processing and assembly gaps and making the brush contact component more stable. Attached Figure Description
[0018] These and / or other aspects and advantages of this application will become clearer and more readily understood from the following detailed description of embodiments of this application taken in conjunction with the accompanying drawings, wherein:
[0019] Figure 1 The diagram illustrates the structure of an existing all-plastic commutator.
[0020] Figure 2 The figure shows a structural schematic diagram of an all-plastic commutator of this application at a certain angle;
[0021] Figure 3 The figure shows a structural schematic diagram of an all-plastic commutator of this application at another angle;
[0022] Figure 4 The diagram shows Figure 2 A magnified view of a portion of point C. Detailed Implementation
[0023] The terms and words used in the following specification and claims are not limited to their literal meaning, but are used solely by the inventors to enable a clear and consistent understanding of this application. Therefore, it will be apparent to those skilled in the art that the following description of various embodiments of this application is provided for illustrative purposes only and not for the purpose of limiting the application as defined in the appended claims and their equivalents.
[0024] It is understood that the term "a" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple, and the term "a" should not be understood as a limitation on the number.
[0025] While ordinal numbers such as "first," "second," etc., will be used to describe various components, there is no limitation on which components are used herein. The term is used only to distinguish one component from another. For example, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component, without departing from the teachings of the utility model concept. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.
[0026] The terminology used herein is for the purpose of describing various embodiments only and is not intended to be limiting. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. It will also be understood that the terms “comprising” and / or “having” as used in this specification specify the presence of the described features, numbers, steps, operations, components, elements or combinations thereof, without excluding the presence or addition of one or more other features, numbers, steps, operations, components, elements or groups thereof.
[0027] Schematic all-plastic commutator, reference Figures 2 to 4 According to a preferred embodiment of the present invention, an all-plastic commutator includes a bakelite powder body 10 and a plurality of commutator segments 20 arranged in a ring array.
[0028] Specifically, such as Figure 2 As shown, the outer wall of the bakelite powder body 10 has a plurality of grooves 101; in addition, each commutator assembly 20 includes a winding member 201 and a brush contact member 202. The winding member 201 is integrally formed with the bakelite powder body 10 by injection molding. The bottom of the brush contact member 202 has a plurality of protrusions 2021. In this embodiment, each brush contact member 202 has two protrusions 2021. Each protrusion 2021 extends into the corresponding groove 101, and one end of the brush contact member 202 abuts against the winding member 201.
[0029] It should be noted that, since the brush contact 202 comes into contact with and wears off during use, by designing the winding member 201 and the brush contact 202 separately, when the brush contact 202 wears out, only the brush contact 202 needs to be replaced, reducing replacement costs. During installation, the protrusion 2021 of the brush contact 202 is inserted into the groove 101.
[0030] Furthermore, to achieve the fixation of the brush contact 202 to the bakelite powder body 10, such as... Figure 2 As shown, the outer wall of the bakelite powder body 10 also has a plurality of first through holes 102, and each groove 101 is connected to the corresponding first through hole 102; in addition, each protrusion 2021 has a second through hole 20211, and the first through hole 102 and the second through hole 20211 are arranged coaxially; in addition, the all-plastic commutator also includes a plurality of insert rods 30, each insert rod 30 corresponding to the commutator assembly 20, and each insert rod 30 is inserted into the corresponding first through hole 102 and second through hole 20211, so that when the bakelite powder body 10 rotates circumferentially, the brush contact 202 does not detach from the bakelite powder body 10.
[0031] However, due to the machining error and assembly gap between the insertion rod 30 and the first through hole 102 and the second through hole 20211, when the insertion rod 30 is inserted into the first through hole 102 and the second through hole 20211, the brush contact 202 has a slight wobble, which aggravates the wear of the brush contact 202 and easily produces abnormal noise.
[0032] Therefore, in the embodiments of this application, as Figure 4As shown, the wall of the second through hole 20211 has an adhesive layer 20212. It should be noted that the adhesive layer 20212 is formed by inserting a axial adhesive roller through the second through hole 20211 before placing the brush contact 202 into the groove 101, creating an adhesive layer 20212 on the wall of the second through hole 20211. Subsequently, the protrusion 2021 of the brush contact 202 extends into the groove 101, and a separate insertion rod 30 is inserted into the corresponding first through hole 102 and second through hole 20211. During insertion, the insertion rod 30 contacts the adhesive layer 20212 on the wall of the second through hole 20211. After the adhesive layer 20212 cures, the position of the insertion rod 30 is fixed, and the insertion rod 30 is bonded to the protrusion 2021. Furthermore, the material of the insertion rod 30 is insulating material such as plastic or ceramic. It is evident that by providing the adhesive layer 20212 within the second through hole 20211, this application achieves the filling of the gap between the insert rod 30 and the first through hole 102 and the second through hole 20211 with adhesive, and thus fixes the insert rod 30. Compared with the prior art, this application has the advantages of being able to fill and eliminate processing and assembly gaps, and making the brush contact more stable.
[0033] Furthermore, in order to abut the end of the insert 30 away from the winding member 201 and disperse any axial force that may exist on the insert 30 elsewhere, the bakelite powder body 10 also has a countersunk hole 103 and an annular groove 104. The countersunk hole 103 is located at the end of the bakelite powder body 10 away from the winding member 201, and the annular groove 104 is located between the countersunk hole 103 and each of the first through holes 102. The all-plastic commutator also includes a retaining spring 40, which is disposed in the annular groove 104 and abuts against one end of the insert 30.
[0034] Furthermore, when the brush contact 202 wears down, in order to remove the brush contact 202, the insertion rod 30 needs to be removed first. To facilitate the removal of the insertion rod 30, as follows: Figure 2 As shown, the bakelite powder body 10 has a plurality of striking holes 105 at the end opposite to the countersunk hole 103. The striking holes 105 extend from the end face of the bakelite powder body 10 opposite to the countersunk hole 103 to the corresponding second through hole 20211 and pass through the winding member 201. It should be noted that the winding member 201 has corresponding holes, which are directly opposite the striking holes 105.
[0035] Furthermore, since the winding component 201 and the bakelite powder body 10 are injection molded as a single unit, in order to improve the connection strength between the winding component 201 and the bakelite powder body 10, such as... Figure 2 As shown, each of the winding members 201 has a trapezoidal groove 2011 at its bottom.
[0036] Furthermore, in the embodiments of this application, such as Figure 2 As shown, the winding member 201 has a winding portion 2012 and a pressure receiving portion 2013 at both ends. The brush contact member 202 has a pressing portion 2022 at one end near the winding member 201. When the first through hole 102 is directly opposite the second through hole 20211, the pressing portion 2022 abuts against the pressure receiving portion 2013.
[0037] It should be noted that the winding part 2012 is used to weld the enameled wire led out from the motor body. By having the pressing part 2022 press the pressing part 2013, the risk of the winding part 201 detaching from the bakelite powder body 10 is further reduced, and the contact between the winding part 201 and the brush contact 202 is achieved.
[0038] Furthermore, such as Figure 3 As shown, the bakelite powder body 10 also has several anti-short-circuit grooves 106. Each pair of adjacent commutator segments 20 has one anti-short-circuit groove 106. Metal debris generated after brush wear falls into the anti-short-circuit groove 106, preventing short circuits between adjacent commutator segments. Additionally, the bakelite powder body 10 has a through hole 107 at its center, and the inner radial dimension of the retaining ring 40 is larger than the diameter of the through hole 107.
[0039] In summary, the all-plastic commutator described in the embodiments of this application is explained, which provides advantages such as filling and eliminating machining and assembly gaps, and more stable brush contacts.
[0040] It is worth mentioning that, in this embodiment, the all-plastic commutator has a simple structure, does not involve complex manufacturing processes or expensive materials, and is highly economical. At the same time, for manufacturers, the all-plastic commutator provided in this application is easy to produce and inexpensive, which is more conducive to controlling production costs and further facilitates product promotion and use.
[0041] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention. The purpose of the present invention has been fully and effectively achieved. The function and structural principle of the present invention have been shown and explained in the embodiments, and any modifications or variations may be made to the implementation of the present invention without departing from these principles.
Claims
1. A full plastic commutator characterized in that: The full-plastic commutator comprises an bakelite body, an outer wall of the bakelite body is provided with a plurality of grooves and a plurality of first through holes, each of the grooves is communicated with a corresponding first through hole; and a plurality of commutator segment combinations arranged in an annular array, each of the commutator segment combinations comprises a winding member and a brush contact member, the winding member is integrally formed with the bakelite body by injection molding, the bottom of the brush contact member is provided with a plurality of protrusions, each of the protrusions is provided with a second through hole, the hole wall of the second through hole is provided with a glue layer, each of the protrusions extends into a corresponding groove, the first through hole and the second through hole are coaxially arranged, and one end of the brush contact member abuts against the winding member; and a plurality of insertion rods, each of the insertion rods corresponds to a commutator segment combination, each of the insertion rods is inserted into a corresponding first through hole and a second through hole.
2. A full plastic commutator according to claim 1, characterized in that: The bakelite body is further provided with a counterbore and an annular clamping groove, the counterbore is located at one end of the bakelite body away from the winding member, the annular clamping groove is located between the counterbore and each of the first through holes, the full-plastic commutator further comprises a clamping spring, the clamping spring is arranged in the annular clamping groove, and one end of the clamping spring abuts against the insertion rod.
3. A full plastic commutator according to claim 2, characterized in that: One end of the bakelite body away from the counterbore is provided with a plurality of knocking holes, the knocking holes extend from the end face of the bakelite body away from the counterbore to a corresponding second through hole and pass through the winding member.
4. A full plastic commutator according to claim 3, characterized in that: The bottom of each of the winding members is provided with a trapezoidal groove.
5. A full plastic commutator according to claim 4, characterized in that: Both ends of the winding member are respectively provided with a winding part and a pressure receiving part, the brush contact member close to one end of the winding member is provided with a pressing part, when the first through hole is aligned with the second through hole, the pressing part abuts against the pressure receiving part.
6. A full plastic commutator according to any one of claims 1-5, characterized in that: The bakelite body is further provided with a plurality of short-circuit prevention grooves, each of the short-circuit prevention grooves is located between two adjacent commutator segment combinations.
7. A full plastic commutator according to any one of claims 2 to 5, characterised in that: The center of the bakelite body is provided with a through hole, the inner side of the clamping spring has a radial dimension greater than the hole diameter of the through hole. The full-plastic commutator comprises