A plowshare cutter, small size commutator and motor

Abstract

The utility model discloses a plough hook tool, small size commutator and motor, plough hook tool is applied to the processing commutator copper shell, and the copper shell includes a plurality of K type inner hooks that are equidistantly arranged along the circumference, and the hook groove is formed between the two adjacent K type inner hooks, the plough hook tool includes the tool bar, first plough, second plough and cushion block, and the first plough is arranged at the outer periphery of the tool bar, and the outer surface of first plough is equipped with a plurality of first plough teeth, the second plough is arranged at the outer periphery of the tool bar, and the second plough is arranged at the one end of the head of first plough away from the tool bar, and the outer surface of second plough is equipped with a plurality of second plough teeth, a plurality of first plough teeth and a plurality of second plough teeth are sequentially alternately arranged along the circumference equidistantly, and the first plough tooth and second plough tooth structure are same, and are used for processing hook groove, and the cushion block is connected between first plough and second plough, the utility model discloses can produce the commutator of the outer diameter greater than or equal to 6.8 millimeter and having K type inner hook in high quality batch.

Description

Technical Field

[0001] This utility model relates to the field of commutator technology, specifically to a plow hook cutter, a small-sized commutator, and a motor. Background Technology

[0002] With increasingly stringent environmental regulations, automotive engine exhaust control technology is constantly evolving. As a key component of the exhaust control system, the electronic wastegate's performance directly impacts exhaust emission levels. And the commutator, as the core component of the electronic wastegate motor, is of paramount importance in terms of size, performance, and reliability.

[0003] Commutators include commutator segments, and the inner hooks of commutator segments are either C-type or K-type. Compared with C-type inner hooks, K-type inner hooks have a larger bonding area and stronger bonding force with the insulating substrate, resulting in superior overall mechanical properties. Therefore, the inner hooks of commutators used in electronic exhaust valve motors in the industry are mostly of the K-type structure. The K-type inner hooks of commutator segments are formed by machining with a cutting tool. Existing cutting tools have multiple plow teeth arranged along the same circumferential direction at the same height, and the gaps between adjacent inner hooks are set one-to-one. However, due to the limitations of the cutting tool structure, when mass-producing commutators with a diameter of less than 7.8 mm and K-type inner hooks, the thin copper shell is easily deformed under the force applied by the plow teeth, which cannot ensure quality. Therefore, there is an urgent need for a cutting tool that can stably mass-produce commutators with a diameter of less than 7.8 mm and K-type inner hooks. Utility Model Content

[0004] In view of this, the present invention provides a plow hook cutter, a small-sized commutator and a motor to solve the problem in the prior art of lacking a cutter capable of stably mass-producing commutators with a diameter of less than 7.8 mm and a K-type inner hook.

[0005] In a first aspect, this utility model provides a plow hook tool for machining the copper shell of a commutator. The copper shell includes multiple K-shaped inner hooks evenly spaced along the circumference, with a hook groove formed between adjacent K-shaped inner hooks. The plow hook tool includes:

[0006] Tool holder;

[0007] A first plow blade is disposed on the outer periphery of the blade holder, and a plurality of first plow blade teeth are provided on the outer surface of the first plow blade.

[0008] The second plow blade is disposed on the outer periphery of the blade handle. The second plow blade is disposed at the end of the first plow blade away from the head of the blade handle. The outer surface of the second plow blade is provided with a plurality of second plow blade teeth. The plurality of first plow blade teeth and the plurality of second plow blade teeth are arranged alternately at equal intervals along the circumference. The first plow blade teeth and the second plow blade teeth have the same structure and are used to process the hook groove.

[0009] A pad is disposed on the outer periphery of the blade holder, and the pad is connected between the first plow blade and the second plow blade.

[0010] The plow hook tool according to this utility model has at least the following beneficial effects:

[0011] By axially spaced first and second plow blades on the tool holder, and alternatingly arranging multiple first and second plow blade teeth at equal intervals circumferentially, with the sum of the number of first and second plow blade teeth equal to the number of hook grooves; when this plow hook tool passes axially through the interior of the commutator's copper shell to machine the commutator's copper shell, the multiple first plow blade teeth first contact the end of the copper shell and machine the corresponding number of hook grooves; after the first plow blade teeth have machined the corresponding number of hook grooves for a certain distance, the second plow blade teeth begin to contact the end of the copper shell. The corresponding number of hook grooves are processed; relative to the first plow blade tooth and the second plow blade tooth simultaneously contacting the end of the copper shell, and processing all the hook grooves, this plow hook tool can reduce the force on the end face of the copper shell, thereby helping to avoid deformation of the copper shell; and the first plow blade and the second plow blade are spaced apart along the axial direction, which can increase the distance between two adjacent first plow blade teeth and the distance between two adjacent second plow blade teeth, so as to reduce the force on a single first plow blade tooth and a single second plow blade tooth when processing the copper shell of the commutator, and avoid problems such as tooth breakage. Simultaneously, by connecting a pad between the first and second plow blades, the second plow blade tooth contacts the end of the copper shell and begins processing the corresponding hook groove just as the first plow blade tooth is nearly finished processing the corresponding hook groove. This transitional action of the pad reduces the stress on the copper shell during the processing of the hook groove by the first and second plow blade teeth, making the thinner copper shell less prone to deformation. This enables high-quality mass production of commutators with an outer diameter greater than or equal to 6.8 mm and featuring a K-type inner hook. The resulting commutators are compact, perform well, and are highly reliable, ensuring that the exhaust control system motor of an automotive engine equipped with a commutator produced using this plow-hook tool meets the requirements for use in high-temperature environments.

[0012] In one optional embodiment, a guide head is provided on the outer periphery of the blade holder. The guide head is located at the end of the first plow blade away from the second plow blade. A guide protrusion is provided on the guide head at the position corresponding to the first plow blade tooth and the second plow blade tooth. The guide protrusion is radially protruding on the outer surface of the guide head.

[0013] In one optional embodiment, a sleeve is further included, the tail of the blade is inserted into the sleeve and can be detachably locked by a locking assembly; a limiting platform is provided on the outer surface of the head of the blade, the first plow blade, the pad block and the second plow blade are sequentially movably sleeved on the blade, the end of the first plow blade away from the pad block abuts against the limiting platform, and the end of the second plow blade away from the pad block abuts against the head end of the sleeve.

[0014] In one optional embodiment, the side wall of the sleeve is provided with a through-hole communicating with the interior of the sleeve, and the locking assembly includes a positioning plug that matches the through-hole; the outer side wall of the blade extending into the sleeve is provided with an arc-shaped groove corresponding to the through-hole, and when the blade and the sleeve are assembled, the positioning plug is inserted into the through-hole and the positioning plug is embedded in the arc-shaped groove.

[0015] Secondly, this utility model also provides a small-sized commutator, comprising:

[0016] Insulating substrate;

[0017] The copper shell is manufactured using the plow hook tool provided in the first aspect above. The copper shell is disposed on the outer peripheral surface of the insulating substrate and is combined with the insulating substrate. The outer diameter of the copper shell is greater than or equal to 6.8 mm. The inner wall of the copper shell is provided with a plurality of K-shaped inner hooks along the circumferential direction. The K-shaped inner hooks are used to connect to the insulating substrate. The space between two adjacent K-shaped inner hooks forms a hook groove.

[0018] The small-sized commutator according to this utility model has at least the following beneficial effects:

[0019] By using a plow-hook tool to machine a high-quality hook groove inside a copper shell with an outer diameter of 6.8 mm or greater, a corresponding K-shaped inner hook is obtained. This allows the outer diameter of this small-sized commutator to be 6.8 mm or greater, resulting in a compact structure, excellent performance, and high reliability. Consequently, the motor of the exhaust gas control system of an automotive engine equipped with this small-sized commutator meets the requirements for use in high-temperature environments. At the same time, the K-shaped inner hook of this small-sized commutator has a large riveting area with the insulating substrate, similar to the shape of a K, resulting in greater bonding force, better product strength, smaller dynamic operating step roundness variation, and lower noise. Therefore, it helps to improve the noise generated by the motor equipped with this small-sized commutator, and can well meet people's daily requirements for high quality, high standards, and low cost.

[0020] In one optional embodiment, an insulating groove is provided on the side wall of the copper shell at the position corresponding to the hook groove. The insulating groove is connected to the hook groove. The plurality of insulating grooves are used to divide the copper shell into a plurality of commutator segments that are insulated from each other. Each commutator segment has a hook on its opposite upper end face along the axial direction. The K-shaped inner hook is provided on the inner wall of the commutator segment at the position corresponding to the hook.

[0021] In one alternative embodiment, the width of the K-type inner hook is set to 0.8 mm to 1.2 mm.

[0022] In one alternative embodiment, the end of the copper shell facing away from the hook along the axial direction is provided as an overlap portion, the inner diameter of the overlap portion being 0.04 mm to 0.06 mm larger than the inner diameter of the hook groove.

[0023] In one optional embodiment, the inner wall of the copper shell is provided with an annular groove, which divides the K-type inner hook into a first inner hook portion and a second inner hook portion. The first inner hook portion is located at the end of the second inner hook portion facing the hook. The end face of the first inner hook portion away from the second inner hook portion is configured as a first inclined surface. The first inclined surface extends radially from the outside to the inside of the copper shell and gradually tilts away from the second inner hook portion axially. A groove is provided on the inner side of the K-type inner hook where it is joined to the insulating substrate. The end of the groove, axially away from the first inclined surface, penetrates the K-type inner hook. The end face of the second inner hook portion away from the first inner hook portion is configured as a second inclined surface. The second inclined surface extends radially from the outside to the inside of the copper shell and gradually tilts away from the first inner hook portion axially. The end face of the second inner hook portion facing the first inner hook portion is parallel to the second inclined surface.

[0024] Thirdly, this utility model also provides a motor, including the small-sized commutator provided in the second aspect above.

[0025] Since the motor includes a small-sized commutator, it has the same beneficial effects as a small-sized commutator, which will not be elaborated here. Attached Figure Description

[0026] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the front view structure of the hook plow cutter in this embodiment;

[0028] Figure 2 for Figure 1 Enlarged view of point A in the middle;

[0029] Figure 3 This is an exploded view of some structures in the hook-plow cutter of this embodiment;

[0030] Figure 4 This is a schematic diagram of the copper shell processed by the plow hook tool in this embodiment.

[0031] Figure 5 This is a three-dimensional structural diagram of the small-sized commutator in this embodiment;

[0032] Figure 6 for Figure 5 A schematic diagram of the structure after the insulation substrate has been removed;

[0033] Figure 7 for Figure 6 Another structural diagram from a different perspective;

[0034] Figure 8 This is a cross-sectional front view of the small-sized commutator in this embodiment.

[0035] Explanation of reference numerals in the attached figures:

[0036] 100-Copper shell, 110-Hook groove, 120-Insulation groove, 130-Commutator segment, 131-Hanging hook, 132-First part, 133-Second part, 140-Overlapping part, 150-Annular groove;

[0037] 200-tool holder, 210-limiting stage, 220-arc groove;

[0038] 300 - First plow blade, 310 - First plow blade tooth;

[0039] 400 - Second plow blade, 410 - Second plow blade tooth;

[0040] 500-pad;

[0041] 600 - Guide head, 610 - Guide protrusion;

[0042] 700 - Rod sleeve, 710 - Positioning plug;

[0043] 800 - Insulating substrate;

[0044] 910 - First inner hook, 911 - First inclined surface, 912 - Third inclined surface, 920 - Second inner hook, 921 - Second inclined surface, 930 - Groove. Detailed Implementation

[0045] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0046] In the description of this embodiment, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this embodiment and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this embodiment. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0047] In the description of this embodiment, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment according to the specific circumstances.

[0048] The following is combined with Figures 1 to 8 The following describes embodiments of the present invention.

[0049] According to a first aspect of the present invention, a plow hook cutter is provided for machining a copper housing 100 of a commutator. The copper housing 100 includes a plurality of K-shaped inner hooks evenly spaced along the circumference, with a hook groove 110 formed between adjacent K-shaped inner hooks. The plow hook cutter includes a cutter bar 200, a first plow blade 300, a second plow blade 400, and a pad block 500. The first plow blade 300 is disposed on the outer periphery of the cutter bar 200, and a plurality of first plow blade teeth 310 are provided on the outer surface of the first plow blade 300. The second plow blade 400 is disposed on the outer periphery of the cutter bar 200. The second plow blade 400 is disposed at the end of the first plow blade 300 away from the head of the blade rod 200. The outer surface of the second plow blade 400 is provided with a plurality of second plow blade teeth 410. The plurality of first plow blade teeth 310 and the plurality of second plow blade teeth 410 are arranged alternately at equal intervals along the circumference. The first plow blade teeth 310 and the second plow blade teeth 410 have the same structure and are used to process the hook groove 110. The pad block 500 is disposed on the outer periphery of the blade rod 200 and the pad block 500 is connected between the first plow blade 300 and the second plow blade 400.

[0050] In this embodiment, the plow hook cutter is constructed by axially spacing a first plow blade 300 and a second plow blade 400 on a cutter shank 200, and alternatingly circumferentially spaced a plurality of first plow blade teeth 310 and a plurality of second plow blade teeth 410, with the sum of the number of first plow blade teeth 310 and second plow blade teeth 410 equal to the number of hook grooves 110. When the plow hook cutter of this embodiment passes axially through the interior of the commutator's copper shell 100 to process the commutator's copper shell 100, the plurality of first plow blade teeth 310 first contact the end of the copper shell 100 and process the corresponding number of hook grooves 110; after the first plow blade teeth 310 have processed a certain distance on the corresponding number of hook grooves 110, the second plow blade teeth 410 begin to contact the commutator. The end of the copper shell 100 is machined with a corresponding number of hook grooves 110. With the first plowshare tooth 310 and the second plowshare tooth 410 simultaneously contacting the end of the copper shell 100 and machining all the hook grooves 110, the plowshare cutter of this embodiment can reduce the force on the end face of the copper shell 100, thereby helping to avoid deformation of the copper shell 100. Furthermore, the first plowshare tooth 300 and the second plowshare tooth 400 are spaced apart along the axial direction, which can increase the distance between two adjacent first plowshare teeth 310 and the distance between two adjacent second plowshare teeth 410, thereby reducing the force on a single first plowshare tooth 310 and a single second plowshare tooth 410 when machining the commutator's copper shell 100, and avoiding problems such as tooth breakage. Simultaneously, by connecting the pad 500 between the first plow blade 300 and the second plow blade 400, the second plow blade tooth 410 only contacts the end of the copper shell 100 and begins to process the corresponding hook groove 110 when the first plow blade tooth 310 is close to completing the processing of the corresponding hook groove 110. That is, through the transitional effect of the pad 500, the stress on the copper shell 100 can be reduced during the processing of the corresponding hook groove 110 by the first plow blade tooth 310 and the second plow blade tooth 410, making the thin copper shell 100 less prone to deformation. This enables the high-quality mass production of commutators with an outer diameter greater than or equal to 6.8 mm and a K-type inner hook. The produced commutators have a compact structure, excellent performance, and high reliability, ensuring that the motor of the automotive engine exhaust control system equipped with the commutator produced by the plow hook cutter of this embodiment meets the requirements for use in high-temperature environments.

[0051] It should be noted that the plow hook cutter of this embodiment can process a commutator with an outer diameter of 6.8 mm with guaranteed quality and quantity. The commutator with an outer diameter of 6.8 mm can improve the mechanical performance of the motor of the automobile engine exhaust control system, increase the motor life and improve market competitiveness; it is also conducive to realizing the lightweighting and miniaturization of automobiles.

[0052] It should be noted that the commutator with an outer diameter greater than or equal to 6.8 mm and a K-shaped inner hook, which is processed by the plow hook tool of this embodiment, has a large joint area with the insulating substrate 800 due to the K-shaped inner hook resembling a K, resulting in greater joint force, better commutator product strength, smaller dynamic operation stage roundness variation, and lower noise. Therefore, it is beneficial to improve the noise generated by the motor equipped with the commutator prepared by the plow hook tool of this embodiment, and can well meet people's daily requirements for high quality, high standards, and low cost.

[0053] It is understandable that the outer diameter of the commutator mentioned in the text (i.e., the outer diameter of the copper shell 100) refers to the diameter of the outer wall surface of the copper shell 100.

[0054] In practical applications, the hook-plow cutter of this embodiment can process commutators with an outer diameter greater than or equal to 6.8 mm and less than 7.8 mm, as well as commutators with a diameter greater than or equal to 7.8 mm.

[0055] It should be noted that the action of the first plow tooth 310 and the second plow tooth 410 in processing the hook groove 110 in this embodiment is similar to the action of "farmers plowing the field". That is, the first plow tooth 310 and the second plow tooth 410 squeeze the inner wall of the copper shell 100, and use the slope designed by the first plow tooth 310 and the second plow tooth 410 to turn the copper up to form the inner hook.

[0056] It should be noted that the ratio of the axial dimension of the groove 930 to the axial dimension of the pad 500 is 0.6 to 0.9, ensuring that the second plow tooth 410 contacts the end of the copper shell 100 and begins to process the corresponding hook groove 110 only after the first plow tooth 310 has processed at least half of the corresponding hook groove 110, that is, after at least part of the first plow tooth 310 extends out of the copper shell 100 towards the head of the tool bar 200.

[0057] like Figures 1 to 5 As shown, in some embodiments, a guide head 600 is provided on the outer periphery of the cutter bar 200. The guide head 600 is located at the end of the first plowshare 300 opposite to the second plowshare 400. A guide protrusion 610 is provided on each position of the guide head 600 corresponding to the first plowshare tooth 310 and the second plowshare tooth 410. The guide protrusion 610 protrudes radially from the outer surface of the guide head 600. The guide protrusion 610 serves to guide and correct deviation, allowing the first plowshare tooth 310 and the second plowshare tooth 410 to more accurately machine the corresponding groove 930 to obtain the inner hook of the commutator. It should be noted that the diameter of the outer wall of the enclosing guide protrusion 610 is smaller than the diameter of the outer wall of the enclosing first plowshare tooth 310. Because the first plowshare tooth 310 and the second plowshare tooth 410 have the same structure, the diameter of the outer wall of the enclosing first plowshare tooth 310 is equal to the diameter of the outer wall of the second plowshare tooth 410.

[0058] In some embodiments, the plow hook cutter further includes a sleeve 700, the tail of the cutter bar 200 is inserted into the sleeve 700 and is detachably locked by a locking assembly; a limiting platform 210 is protruding from the outer surface of the head of the cutter bar 200, the first plow blade 300, the pad block 500 and the second plow blade 400 are sequentially movably sleeved on the cutter bar 200, the end of the first plow blade 300 away from the pad block 500 abuts against the limiting platform 210, and the end of the second plow blade 400 away from the pad block 500 abuts against the head end of the sleeve 700. This configuration allows the cutter bar 200, the first plow blade 300, the pad block 500, the second plow blade 400, and the sleeve 700 to be separated, making it easier to process the five components separately before assembly, thus reducing manufacturing costs. During assembly, the first plow blade 300, the pad block 500, and the second plow blade 400 are first sequentially fitted onto the cutter bar 200 from the tail end. Then, the tail end of the cutter bar 200 is inserted into the sleeve 700 until the second plow blade 400 abuts against the head end of the sleeve 700 and the first plow blade 300 abuts against the limiting platform 210. Finally, the locking assembly is tightened to complete the assembly. The entire assembly operation is simple.

[0059] like Figure 1 and Figure 2 As shown, specifically, the side wall of the sleeve 700 is provided with a plug hole that communicates with the interior of the sleeve 700, and the locking assembly includes a positioning plug 710 that matches the plug hole; the outer side wall of the blade 200 extending into the sleeve 700 is provided with an arc-shaped groove 220 corresponding to the plug hole. With this configuration, when assembling the plow hook cutter of this embodiment, the first plow blade 300, the pad block 500, and the second plow blade 400 are first sequentially fitted onto the blade rod 200 from the tail end. Then, the tail end of the blade rod 200 is inserted into the inside of the sleeve 700 until the second plow blade 400 abuts against the head end of the sleeve 700. At this time, the arc-shaped groove 220 is aligned with the insertion hole. Then, the positioning plug 710 is inserted into the insertion hole, so that the positioning plug 710 is embedded in the arc-shaped groove 220 to form a snap-fit, thereby completing the assembly. When disassembling the plow hook cutter of this embodiment, it is only necessary to pull the positioning plug 710 out of the insertion hole. The entire disassembly and assembly process is simple to operate.

[0060] According to a second aspect of the present invention, a small-sized commutator is also provided, including an insulating substrate 800 and a copper shell 100. The copper shell 100 is manufactured using a plow hook tool provided in the first aspect of the present invention. The copper shell 100 is disposed on the outer peripheral surface of the insulating substrate 800 and is combined with the insulating substrate 800. The outer diameter of the copper shell 100 is greater than or equal to 6.8 mm. A plurality of K-shaped inner hooks are provided circumferentially on the inner wall of the copper shell 100. The K-shaped inner hooks are used to connect the insulating substrate 800. The space between two adjacent K-shaped inner hooks forms a hook groove 110.

[0061] The plow hook tool provided in the first aspect of the present invention can perform high-quality machining of the hook groove 110 inside the copper shell 100 with an outer diameter greater than or equal to 6.8 mm to obtain the corresponding K-type inner hook. This allows the small-sized commutator of the present invention to have an outer diameter greater than or equal to 6.8 mm based on the K-type inner hook. As a result, the small-sized commutator of the present invention has a compact structure, excellent performance, and high reliability. Consequently, the motor of the exhaust gas control system of the automobile engine equipped with the small-sized commutator of the present invention meets the requirements for use in high-temperature environments. At the same time, the K-type inner hook of the small-sized commutator of the present invention has a large riveting joint area with the insulating substrate 800, similar to the shape of a K, resulting in greater joint force. The commutator product has good strength, small dynamic operation stage roundness change, and lower noise. Therefore, it is beneficial to improve the noise generated by the motor equipped with the small-sized commutator of the present invention, and can well meet people's daily requirements for high quality, high standards, and low cost.

[0062] It is understood that the axial direction mentioned in the text refers to the axial direction of the copper shell 100, which is parallel to the axial direction of the tool holder 200. For ease of description, this is used... Figure 1 The axial direction in the text is described as the axial direction.

[0063] Specifically, the outer diameter of the small-sized commutator in this embodiment is 6.8 mm, which can better meet the miniaturized motor design requirements of motor manufacturers, thereby facilitating the lightweighting and miniaturization of automobiles.

[0064] Specifically, the insulating substrate 800 is made of bakelite powder material of brand PD8580BK, which gives the insulating substrate 800 better heat resistance and less deformation in high-temperature environments (i.e., it can work stably in an ambient temperature range of -40℃ to 215℃). This avoids the problem of large deformation of the insulating substrate 800 at 215℃, which would lead to large changes in the roundness and step difference of the copper sheet, thus meeting the requirements of electronic waste gas valve motors for use in high-temperature environments.

[0065] like Figures 5 to 8As shown, in some embodiments, an insulating groove 120 is provided on the side wall of the copper shell 100 at a position corresponding to the hook groove 110. The insulating groove 120 communicates with the hook groove 110. Multiple insulating grooves 120 are used to divide the copper shell 100 into multiple mutually insulated commutator segments 130. Each commutator segment 130 has a hook 131 on its axially opposite upper surface. A K-shaped inner hook is provided on the inner wall of the commutator segment 130 at a position corresponding to the hook 131. This arrangement ensures that a K-shaped inner hook is provided at the position of each hook 131, maintaining the same bonding force between each commutator segment 130 and the insulating substrate 800. This bonding force is relatively large, resulting in good product strength, small dynamic operation stage roundness variation, and lower noise.

[0066] It is understandable that the diameter of the outer wall surface of the copper shell 100 mentioned in the text (i.e., the outer diameter of the copper shell 100) refers to the diameter of the outer wall surface of the enclosed commutator segment 130.

[0067] Specifically, the commutator segment 130 is made of high-performance 3Ag-OFCu copper alloy material with a hardness controlled at HV105min, and has good conductivity, wear resistance and high temperature resistance.

[0068] like Figure 6 and Figure 7 As shown, specifically, the commutator segment 130 includes a first part 132 and a second part 133. A hook 131 is disposed at the end of the first part 132 opposite to the second part 133. The outer diameter of the second part 133 is 0.08 mm to 0.12 mm larger than the outer diameter of the first part 132. In this embodiment, it is preferably 0.1 mm larger, which helps to improve the connection strength between the hook 131 and the commutator segment 130. Here, the outer diameter of the copper shell 100 refers to the diameter of the outer wall surface of the enclosed commutator segment 130 near the end of the hook 131.

[0069] In some embodiments, the width of the K-type inner hook is set to 0.8 mm to 1.2 mm, preferably 1 mm. This ensures that the number of K-type inner hooks is 8 and the outer diameter of the commutator is 6.8 mm. On the one hand, it avoids the problem that the inner hook width is too small, resulting in insufficient strength and making it impossible to process and form. On the other hand, it avoids the problem that the hook groove 110 width is too small due to the inner hook width being too large, resulting in the plow teeth being too small and lacking strength, thus making it impossible to form.

[0070] like Figure 7 and Figure 8As shown, in some embodiments, the end of the copper shell 100 that is axially away from the hook 131 is provided as an overlap portion 140. The inner diameter of the overlap portion 140 is 0.04 mm to 0.06 mm larger than the inner diameter of the hook groove 110, preferably 0.05 mm. Because the outer diameter of the copper shell 100 in this embodiment is 6.8 mm and the weight is relatively light, the thickness of the overlap portion 140 is smaller than the thickness of the copper shell 100, which can still withstand the weight of the copper shell 100 without deformation and meet production needs. This reduces the difference between the inner diameter of the overlap portion 140 and the inner diameter of the hook groove 110 from the original 0.1 mm to 0.05 mm. This can both increase the diameter of the first plow tooth 310 and the second plow tooth 410 to improve the strength of the plow teeth, and avoid burrs being scraped off when processing the hook groove 110 by encountering the overlap portion 140.

[0071] Specifically, the wall thickness of the copper shell 100 after the processing of groove 930 is 0.65 mm, and the wall thickness of the overlapping part 140 is 0.6 mm.

[0072] like Figure 6 and Figure 8As shown, in some embodiments, the inner wall of the copper shell 100 is provided with an annular groove 150, which is used to divide the K-type inner hook into a first inner hook portion 910 and a second inner hook portion 920. The first inner hook portion 910 is located at the end of the second inner hook portion 920 facing the hook 131. The end face of the first inner hook portion 910 away from the second inner hook portion 920 is provided as a first inclined surface 911. The first inclined surface 911 extends from the outside to the inside along the radial direction of the copper shell 100 and gradually tilts away from the second inner hook portion 920 along the axial direction. The inner side of the K-shaped inner hook that is connected to the insulating substrate 800 is provided with a groove 930. The end of the groove 930 that is axially away from the first inclined surface 911 passes through the K-shaped inner hook. The end face of the second inner hook portion 920 that is away from the first inner hook portion 910 is provided as a second inclined surface 921. The second inclined surface 921 extends radially from the outside to the inside of the copper shell 100 and is gradually inclined away from the first inner hook portion 910 along the axial direction. The end face of the second inner hook portion 920 facing the first inner hook portion 910 is parallel to the second inclined surface 921. In the process of injection molding the copper shell 100 and the insulating substrate 800 to obtain the commutator of this embodiment, the annular groove 150 is filled with the insulating substrate 800, so that the space between the first inner hook portion 910 and the second inner hook portion 920 is filled with the insulating substrate 800. This allows the first inner hook portion 910 and the second inner hook portion 920 to work together to restrict the axial degree of freedom of the portion of the insulating substrate 800 located between them, thereby increasing the axial tensile strength of the combination between the copper shell 100 and the insulating substrate 800 in the commutator of this embodiment. At the same time, by having both ends of the second inner hook portion 920 inclined along the axial direction, the sides of the second inner hook portion 920 are arranged in a parallelogram shape, further improving the bonding strength between the commutator segment 130 and the insulating substrate 800 of the commutator of this embodiment. Furthermore, by having the groove 930 pass through the K-shaped inner hook at one end along the axial direction away from the first inclined surface 911. In the process of injection molding the copper shell 100 and the insulating substrate 800 to obtain the commutator of this embodiment, the insulating substrate 800 can fill the groove 930. That is, the portion of the insulating substrate 800 located in the groove 930 is circumferentially limited by the two walls of the groove 930, further increasing the circumferential tensile strength of the combination of the copper shell 100 and the insulating substrate 800 in the commutator of this embodiment. Furthermore, the first inclined surface 911 covers the top of the groove 930, so that the portion of the insulating substrate 800 located in the groove 930 is in contact with the bottom of the first inclined surface 911, and cooperates with the portion of the insulating substrate 800 covering the top of the first inclined surface 911, further increasing the axial tensile strength of the combination of the copper shell 100 and the insulating substrate 800 in the commutator of this embodiment, that is, further improving the bonding strength between the commutator segment 130 and the insulating substrate 800 in the commutator of this embodiment.

[0073] Specifically, the angle between the arrangement direction of the first inclined surface 911 and the axial direction is set to an acute angle. During the injection molding process of the copper shell 100 and the insulating substrate 800 to obtain the commutator of this embodiment, the first inclined surface 911, which is inclined at an acute angle, can better increase the axial tensile strength of the combination of the copper shell 100 and the insulating substrate 800 in the commutator of this embodiment, and further improve the bonding strength between the commutator segment 130 and the insulating substrate 800 in the commutator of this embodiment.

[0074] like Figure 8 As shown, specifically, the end face of the first inner hook portion 910 facing the second inner hook portion 920 is configured as a third inclined surface 912. The radial direction of the copper shell 100 of the third inclined surface 912 extends from the outside to the inside, and gradually approaches the second inner hook portion 920 along the axial direction at an inclined angle. With this configuration, the side of the first inner hook portion 910 is arranged in a shape similar to an "isosceles trapezoid", which further improves the bonding strength between the commutator segment 130 and the insulating substrate 800 of the commutator in this embodiment.

[0075] According to a third aspect of the present invention, an electric motor is also provided, which further includes a small-sized commutator provided in a second aspect of the present invention. The copper housing 100 of the commutator in this embodiment is manufactured using a plow-hook tool provided in a first aspect of the present invention, resulting in an outer diameter of the commutator greater than or equal to 6.8 mm and a K-shaped inner hook. This makes the commutator in this embodiment compact, high-performance, and highly reliable, thus enabling the motor to meet the requirements for use in high-temperature environments. Furthermore, the K-shaped inner hook, resembling a K-shape, allows for a large riveting area and stronger bonding force with the insulating substrate 800, resulting in better commutator strength, smaller dynamic operating step roundness changes, and lower noise. Therefore, it helps to reduce the noise generated by assembling the motor in this embodiment, effectively meeting people's daily requirements for high quality, high standards, and low cost.

[0076] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and all such modifications and variations fall within the scope defined by the appended invention.

Claims

1. A plow hook tool, used for machining the copper shell (100) of a commutator, the copper shell (100) comprising a plurality of K-shaped inner hooks equally spaced along the circumference, wherein a hook groove (110) is formed between two adjacent K-shaped inner hooks, characterized in that, The plow hook cutter includes: Tool holder (200); A first plow blade (300) is disposed on the outer periphery of the blade bar (200), and a plurality of first plow blade teeth (310) are provided on the outer surface of the first plow blade (300); The second plow blade (400) is disposed on the outer periphery of the blade rod (200). The second plow blade (400) is disposed at the end of the first plow blade (300) away from the head of the blade rod (200). The outer surface of the second plow blade (400) is provided with a plurality of second plow blade teeth (410). The plurality of first plow blade teeth (310) and the plurality of second plow blade teeth (410) are arranged alternately at equal intervals along the circumferential direction. The first plow blade teeth (310) and the second plow blade teeth (410) have the same structure and are used to process the hook groove (110). A pad (500) is disposed on the outer periphery of the blade (200) and the pad (500) is connected between the first plow blade (300) and the second plow blade (400).

2. A plow hook cutter according to claim 1, characterized in that, A guide head (600) is provided on the outer periphery of the blade (200). The guide head (600) is located at the end of the first plow blade (300) away from the second plow blade (400). The guide head (600) is provided with a guide protrusion (610) at the position corresponding to the first plow blade tooth (310) and the second plow blade tooth (410). The guide protrusion (610) is radially protruding on the outer surface of the guide head (600).

3. A plow hook cutter according to claim 1, characterized in that, It also includes a sleeve (700), the tail of the blade (200) is inserted into the sleeve (700) and can be detachably locked by a locking assembly; a limiting platform (210) is provided on the outer surface of the head of the blade (200), the first plow blade (300), the pad block (500) and the second plow blade (400) are sequentially movably sleeved on the blade (200), the end of the first plow blade (300) away from the pad block (500) abuts against the limiting platform (210), and the end of the second plow blade (400) away from the pad block (500) abuts against the head end of the sleeve (700).

4. A plow hook cutter according to claim 3, characterized in that, The side wall of the sleeve (700) is provided with a through-hole that communicates with the interior of the sleeve (700). The locking assembly includes a positioning plug (710) that matches the through-hole. The outer side wall of the blade (200) extending into the sleeve (700) is provided with an arc-shaped groove (220) corresponding to the through-hole. When the blade (200) and the sleeve (700) are assembled, the positioning plug (710) is inserted into the through-hole and the positioning plug (710) is embedded in the arc-shaped groove (220).

5. A small-sized commutator, characterized in that, include: Insulating substrate (800); The copper shell (100) is manufactured using the plow hook tool as described in any one of claims 1 to 4. The copper shell (100) is disposed on the outer peripheral surface of the insulating substrate (800) and is combined with the insulating substrate (800). The outer diameter of the copper shell (100) is greater than or equal to 6.8 mm. The inner wall of the copper shell (100) is provided with a plurality of K-shaped inner hooks along the circumferential direction. The K-shaped inner hooks are used to connect the insulating substrate (800). The space between two adjacent K-shaped inner hooks forms a hook groove (110).

6. A small-size commutator according to claim 5, characterized in that, An insulating groove (120) is provided on the side wall of the copper shell (100) at the position corresponding to the hook groove (110). The insulating groove (120) is connected to the hook groove (110). The multiple insulating grooves (120) are used to divide the copper shell (100) into multiple commutator segments (130) that are insulated from each other. Each commutator segment (130) has a wire hook (131) on its opposite upper end face along the axial direction. The K-type inner hook is provided on the inner wall of the commutator segment (130) at the position corresponding to the wire hook (131).

7. A small-size commutator according to claim 5, characterized in that, The width of the K-type inner hook is set to be between 0.8 mm and 1.2 mm.

8. A small-size commutator according to claim 6, characterized in that, The copper shell (100) is provided with an overlap portion (140) at one end axially away from the hook (131), and the inner diameter of the overlap portion (140) is 0.04 mm to 0.06 mm larger than the inner diameter of the hook groove (110).

9. A small-size commutator according to claim 6, characterized in that, The inner wall of the copper shell (100) is provided with an annular groove (150), which is used to divide the K-type inner hook into a first inner hook portion (910) and a second inner hook portion (920). The first inner hook portion (910) is located at the end of the second inner hook portion (920) facing the hook (131). The end face of the first inner hook portion (910) away from the second inner hook portion (920) is set as a first inclined surface (911). The first inclined surface (911) extends from the outside to the inside along the radial direction of the copper shell (100) and gradually tilts away from the second inner hook portion (920) along the axial direction. A groove (930) is provided on the inner side of the inner hook that is combined with the insulating substrate (800). The end of the groove (930) that is axially away from the first inclined surface (911) passes through the K-shaped inner hook. The end face of the second inner hook part (920) that is away from the first inner hook part (910) is set as a second inclined surface (921). The second inclined surface (921) extends from the outside to the inside along the radial direction of the copper shell (100) and is inclined away from the first inner hook part (910) along the axial direction. The end face of the second inner hook part (920) facing the first inner hook part (910) is parallel to the second inclined surface (921).

10. An electric motor, characterized in that, Includes the small-sized commutator according to any one of claims 5 to 9.

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