An end face commutator armature

Abstract

The utility model relates to a direct current motor structure field discloses an end face commutator armature, including armature shaft, armature core, end face commutator and armature wire. The armature shaft passes through the center through -hole on the armature core and end face commutator in proper order, the end face commutator contains a plurality of circumferential distribution's commutator sheet, and the commutator sheet end is equipped with the claw portion of axial bending, the armature core is along the circumferential and is set up a plurality of line grooves, the armature wire is a continuous wire, and it is reciprocatingly threaded in the line groove and forms multiple turns coil, and the first end, the end and a plurality of intermediate end of this armature wire are respectively twisted and tin solder fixed on the claw portion of different commutator sheet. The structure passes through end face commutator and single wire lamination design, shortens armature axial dimension significantly, reduces copper material consumption, simplifies winding and welding technology, reduces production cost, effectively inhibits electric spark simultaneously, reduces carbon brush wear, prolongs motor service life, and is applicable to small -power direct current direct drive motor.

Description

Technical Field

[0001] This utility model relates to the field of DC motor structure and discloses an end-face commutator armature. Background Technology

[0002] The armature is the core component of a DC motor (especially a starter). As the carrier of current, it generates electromagnetic torque and outputs torque through the principle of electromagnetic induction to drive related mechanisms. Currently, common low-power DC motors generally use radial commutator armatures, which achieve current commutation through the sliding contact between the commutator and the carbon brushes.

[0003] However, during the development of this utility model, it was discovered that the radial commutator armature design in the prior art has significant limitations. First, this structure results in a longer axial dimension of the armature, making the overall motor structure less compact and increasing the amount of copper used in the commutator segments, leading to higher material costs. Second, in terms of manufacturing, the winding of the armature coil often requires specialized winding equipment and tooling molds, and the connection between the coil and the radial commutator segments must be welded using specialized spot welding equipment, making the process complex and costly, unsuitable for small-batch or flexible production. Furthermore, in terms of performance, due to structural and current characteristics limitations, the commutator segments and carbon brushes are prone to generating large electrical sparks during contact and rotation, which accelerates carbon brush wear and consequently affects the overall service life of the motor.

[0004] While some armature designs exist on the market that aim to simplify manufacturing processes or optimize structure, they generally struggle to achieve a good balance between cost, manufacturing complexity, and performance reliability. For example, some armatures employing simplified connection methods often have lower connection reliability and electrical performance than those using traditional welding methods, making it difficult to meet the high torque and high reliability requirements of starter motors.

[0005] In summary, existing technologies lack an armature solution that simultaneously achieves a compact structure, low material and manufacturing costs, simple production processes, and a longer service life. Therefore, there is an urgent need for an innovative armature structure and connection scheme to overcome the shortcomings of existing technologies and meet the increasingly stringent requirements of cost, performance, and manufacturing processes for low-power DC motors, especially starters. Utility Model Content

[0006] This utility model discloses an end-face commutator armature, which can realize the axial compact design of the motor structure and significantly reduce material and production costs. It significantly shortens the armature shaft length and simplifies the winding and welding process. At the same time, it effectively solves the systemic problems of large axial dimensions, high copper consumption of commutator segments, reliance on specialized equipment for winding and welding, and large commutation electric sparks in traditional radial commutator armatures.

[0007] To achieve the above objectives, this utility model provides an end-face commutator armature, including an armature shaft, an armature core, an end-face commutator, and armature wires. The armature core has a first through hole at its center and is fixedly sleeved on the armature shaft through the first through hole. The end-face commutator has a second through hole at its center and is fixed to one axial end of the armature shaft through the second through hole. The end face commutator includes multiple commutator segments fixed thereon and distributed circumferentially, each commutator segment having a hook portion bent axially at its end; The armature core has multiple slots along its circumference; The armature wire is a continuous conductor that is repeatedly wound in multiple slots of the armature core to form a multi-turn coil. The armature wire includes a start end, an end end, and multiple intermediate ends, which are respectively wound and fixed on different hooks.

[0008] Optionally, the armature wire and the hook may be fixed by soldering.

[0009] Optionally, the section of the armature shaft that contacts the first through hole is provided with a knurled structure.

[0010] Optionally, the section of the armature shaft that contacts the second through hole is provided with a knurled structure.

[0011] Optionally, slot insulation paper is provided on the inner wall of each slot of the armature core.

[0012] Optionally, each slot of the armature core is also fitted with a slot wedge to press the slot insulation paper and armature wire together.

[0013] Optionally, the slot wedge is made of an insulating rigid plate.

[0014] Optionally, insulating end plates are provided at both ends of the armature core along its axial direction.

[0015] Optionally, each slot of the armature core is covered with a sealed epoxy coating.

[0016] Optionally, each slot of the armature core contains 16 turns of armature wire, and the armature wire is a copper wire with a diameter of 1 mm.

[0017] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model include at least the following: This invention, through an innovative structure combining an end-face hook-shaped commutator with a single continuous conductor wound sequentially, achieves a reduction in the axial dimension of the armature and a significant decrease in material costs. It solves the systemic problems of excessive shaft length, high copper consumption, and complex manufacturing processes inherent in traditional radial commutator armatures. Simultaneously, by employing a tin-bonded connection method between the coil and commutator segment hooks, a knurled structure on the armature shaft mating section, and a comprehensive insulation and fixing design using slot insulating paper, slot wedges, and epoxy varnish, the winding and welding processes are greatly simplified, reducing reliance on specialized equipment. This effectively suppresses commutation sparks and prevents high-speed wire slippage, significantly improving production efficiency and cost advantages. Furthermore, its compact structure and high operational reliability greatly extend the motor's service life, providing a low-cost, highly reliable, and easily manufactured core armature component option for small-power DC motors. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a structural diagram of the armature of this utility model; Figure 2 This is a schematic diagram of the armature wiring of this utility model; Figure 3 This is a front view of the end-face commutator of this utility model; Figure 4 This is a cross-sectional view of the armature core of this utility model; Figure 5 This is a cross-sectional view of the insulating end plate of this utility model; Figure 6 This is a structural diagram of the wire groove of this utility model; Figure 7 This is a structural diagram of the armature shaft of this utility model.

[0020] In the diagram: 1-Armature shaft, 2-Armature core, 3-End face commutator, 4-Armature wire, 5-Insulating end plate, 201-Wire groove, 202-Groove insulation paper, 203-Groove wedge, 204-First through hole, 205-Knurled structure, 206-Knurled structure, 301-Commutator segment, 302-Second through hole, 3011-Hook. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be described in detail below. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0022] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0023] Example 1 Please see Figures 1 to 7 The present invention provides an end-face commutator armature, comprising: an armature shaft 1, an armature core 2, an end-face commutator 3, and an armature wire 4.

[0024] The armature core 2 has a first through hole 204 machined at its center, and is fixedly sleeved on the armature shaft 1 through the first through hole 204 with an interference fit. To achieve a more secure fit and prevent relative rotation, the section of the armature shaft 1 in contact with the first through hole 204 is machined with a knurled structure 205. The end face commutator 3 is an end face hook-shaped commutator with a second through hole 302 at its center, and is fixed to one axial end of the armature shaft 1 with an interference fit through the second through hole 302. Similarly, the section of the armature shaft 1 in contact with the second through hole 302 is also machined with a knurled structure 205 to enhance connection reliability. The end face commutator 3 includes a base and a plurality of commutator segments 301 fixed thereon in a circumferentially distributed manner, and the end of each commutator segment 301 is provided with a hook portion 3011 bent axially. The armature core 2 has a plurality of grooves 201 opened in the circumferential direction. To ensure insulation, the inner wall of each slot 201 is lined with slot insulation paper 202. Insulating end plates 5 are also provided at both axial ends of the armature core 2 to provide end insulation. The armature wire 4 is a continuous copper conductor with a diameter of 1 mm. The armature wire 4 is wound repeatedly in the multiple slots 201 of the armature core 2 according to a specific rule, ultimately forming a 16-turn coil in each slot 201. During the winding process, the beginning, end, and multiple intermediate ends of the armature wire 4 are guided to the commutator 3 side and respectively wound and fixed onto the hooks 3011 of different commutator segments 301. To ensure a firm and reliable electrical connection, the winding joint between the armature wire 4 and the hooks 3011 is fixed by soldering. To further secure the internal structure, each slot 201 of the armature core 2 is also fitted with a slot wedge 203. The slot wedge 203 is used to press the slot insulation paper 202 and the armature wire 4 together, preventing them from loosening. In this embodiment, the slot wedge 203 is preferably made of 3240 epoxy glass cloth board, which has excellent insulation properties and mechanical strength.

[0025] Finally, to improve the overall stability and insulation, each slot 201 of the armature core 2 and the coil end of the armature wire 4 are covered with an epoxy varnish layer (not shown separately in the figure) that is heated, dripped and cured. This epoxy varnish layer can effectively prevent wires from flying off when the armature rotates at high speed and ensure that the coils are mutually insulated.

[0026] The armature assembly process in this embodiment is as follows: First, the armature shaft 1 is pressed into the first through hole 204 of the armature core 2 to the predetermined position. Then, the end-face commutator 3 is pressed into the end of the armature shaft 1, ensuring that the mica center of the commutator segment 301 is aligned with the center of the slot 201 of the armature core 2. Next, slot insulation paper 202 is embedded in the core slot 201. Then, using a single continuous 1mm copper wire as the armature wire 4, it is wound according to the predetermined rule of "slot span 1-5, commutator segment 301 distance 1-2", with two layers of winding to achieve 16 turns per slot. During the winding process, multiple connecting ends of the armature wire 4 are sequentially wound onto the corresponding hook portion 3011 of the commutator segment 301. After winding, the winding points are hot-soldered. Finally, slot wedges 203 made of 3240 epoxy glass cloth are embedded in the slot 201 to tighten the internal structure. Finally, the entire armature assembly is heated, and epoxy paint is evenly dripped onto the coil ends and the surface of the iron core. After curing, a solidified epoxy paint layer is formed, completing the manufacturing of the entire armature.

[0027] The technical solution provided in this embodiment is as follows: The armature working process provided in this embodiment is as follows: When the motor starts, the current is transmitted to the commutator segment 301 of the end face commutator 3 via the carbon brush. The current is conducted through the hook portion 3011 of the commutator segment 301 to the coil wound with the armature wire 4, energizing the coil. After being energized, the armature wire 4 is subjected to the Ampere force in the magnetic field, generating a continuous electromagnetic torque based on the principle of electromagnetic induction, driving the entire armature to rotate around its axis. The front end of the armature shaft 1 is configured to transmit torque (for example, by providing a spur spline), thereby outputting the electromagnetic torque. In this process, due to the use of the end face commutator 3 structure and the thinner wire diameter and smaller operating current of the armature wire 4, the electrical sparks at the contact surface between the commutator segment 301 and the carbon brush are significantly reduced. This not only reduces the wear of the carbon brush, but also contributes to extending the overall service life of the motor from the core component level.

[0028] Example 2 Based on Embodiment 1, this embodiment further defines the specific winding path of the armature wire 4 to explain its implementation in detail. The 16 slots 201 on the armature core 2 are sequentially labeled a1 to a16, and the 16 hooks 3011 on the end face commutator 3 are sequentially labeled b1 to b16.

[0029] The specific winding path of the armature wire 4 is as follows: The starting end of the armature wire 4 is first fixed to the hook 3011b1, then it passes through the wire groove 201a5 in a counterclockwise direction and exits from the wire groove 201a1. It is wound back and forth 4 times between the wire groove 201a1 and a5 to form a coil unit. After completing this unit, the armature wire 4 is wrapped around and fixed to the next hook 3011b2. Then, starting from the hook 3011b2, it passes through the wire groove 201a6 in a counterclockwise direction and exits from the wire groove 201a2. It is wound 4 times between the wire groove 201a2 and a6. After that, the armature wire 4 is wrapped around and fixed to the hook 3011b3.

[0030] Following this pattern, armature wire 4 always follows the rule of "starting from the current hook 3011, passing through the far end slot 201 with a spacing of 4 slots, exiting from the adjacent near end slot 201, winding 4 turns, and then fixing to the next sequential hook 3011". It passes through hook 3011b4 and slots 201a7, a3, hook 3011b5 and slots 201a8, a4, etc., until finally being fixed around hook 3011b16, and completing the winding between slots 201a16 and a4. Thus, using a continuous conductor, strictly following the rule of "slot span 1-5, commutator segment 301 distance 1-2", it winds two rounds in sequence, finally forming a total of 16 turns of coil in each slot 201, and establishing a one-to-one and reliable electrical connection with all 16 hooks 3011.

[0031] The above winding path clearly defines the spatial positional relationship and electrical connection structure between the armature wire 4, the slot 201, and the hook 3011, which is the key to realizing the compact armature structure and excellent performance of this utility model.

[0032] Based on the specific structures and processes described in Embodiments 1 and 2, the beneficial effects brought about by this utility model are specifically realized: By replacing the traditional radial commutator with the end-face commutator 3 and integrating it with the armature shaft 1 at the same axial end, the axial length of the armature is effectively shortened, making the motor structure more compact. This also directly reduces the amount of copper used in the commutator segments 301, lowering material costs. By using a single continuous armature wire 4 and strictly adhering to the rule of "slot span 1-5, commutator segment 301 spacing 1-2" for winding, manual winding of the coil is achieved, eliminating the need for specialized winding equipment and tooling molds. Simultaneously, the connection between the armature wire 4 and the hook portion 3011 of the commutator segments 301 is achieved through winding followed by soldering, replacing the traditionally required specialized spot welding equipment and greatly simplifying the welding process. These two points combined significantly reduce the manufacturing cost of the armature and the reliance on specialized equipment. Furthermore, due to the small diameter (1mm) of the armature wire 4, its operating resistance is relatively high, resulting in a smaller normal operating current. Combined with the tight contact between the commutator segment 301 and the carbon brushes via spring tension, this significantly reduces electrical sparks generated during commutation, effectively reducing carbon brush wear and extending the overall service life of the motor. The knurled structure 205 at the fit between the armature shaft 1, the armature core 2, and the end face commutator 3 enhances the reliability of the interference fit and prevents relative rotation. The combined application of slot insulating paper 202, slot wedge 203, insulating end plate 5, and the sealing epoxy coating ensures reliable insulation between the coil and the core, as well as between the coils themselves, effectively preventing wire slippage caused by centrifugal force during high-speed armature operation, thus improving the product's structural stability and operational reliability.

[0033] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0034] Furthermore, it should be noted that the scope of the methods and apparatus in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. In addition, features described with reference to certain examples may be combined in other examples.

[0035] The above description is only a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model.

Claims

1. An end-face commutator armature, comprising an armature shaft (1), an armature core (2), an end-face commutator (3), and armature wires (4), wherein the armature core (2) has a first through hole (204) at its center and is fixedly sleeved on the armature shaft (1) through the first through hole (204), and the end-face commutator (3) has a second through hole (302) at its center and is fixed to one axial end of the armature shaft (1) through the second through hole (302), characterized in that: The end face commutator (3) includes a plurality of commutator segments (301) fixed thereon and distributed in the circumferential direction, and each of the commutator segments (301) has a hook (3011) bent in the axial direction at its end. The armature core (2) has multiple slots (201) along its circumference. The armature wire (4) is a continuous conductor that is repeatedly wound in multiple slots (201) of the armature core (2) to form a multi-turn coil. The armature wire (4) includes a start end, an end end and multiple intermediate ends, which are respectively wound and fixed on different hooks (3011).

2. The end-face commutator armature according to claim 1, characterized in that: The armature wire (4) and the hook (3011) are fixed by soldering at the point where they are wrapped together.

3. The end-face commutator armature according to claim 1, characterized in that: The section of the armature shaft (1) that contacts the first through hole (204) is provided with a knurled structure (205).

4. The end-face commutator armature according to claim 1, characterized in that: The section of the armature shaft (1) that contacts the second through hole (302) is provided with a knurled structure (205).

5. The end-face commutator armature according to claim 1, characterized in that: Each of the slots (201) of the armature core (2) is provided with slot insulation paper (202) on the inner wall.

6. The end-face commutator armature according to claim 5, characterized in that: Each of the slots (201) of the armature core (2) is further embedded with a slot wedge (203) for pressing the slot insulation paper (202) and the armature wire (4).

7. The end-face commutator armature according to claim 6, characterized in that: The slot wedge (203) is made of an insulating rigid plate.

8. The end-face commutator armature according to claim 1, characterized in that: Insulating end plates (5) are provided at both ends of the armature core (2) along its axial direction.

9. The end-face commutator armature according to claim 1, characterized in that: Each slot (201) of the armature core (2) is covered with a sealed epoxy paint layer at the slot opening.

10. The end-face commutator armature according to claim 6, characterized in that: Each of the slots (201) of the armature core (2) contains 16 turns of the armature wire (4), and the armature wire (4) is a copper wire with a diameter of 1 mm.

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