Commutator Connector Layout for Pre-Mounted Ring Varistors
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Solution Overview
Problem
The existing methods for installing ring-shaped varistors in commutators are inefficient, requiring manual installation, leading to reduced production efficiency and potential coil damage, and are not conducive to optimizing the production process or ensuring electromagnetic compatibility in micromotors.
Innovation Solution
A commutator design with integrally formed connectors and a cylindrical structure that allows for the prior installation of ring-shaped varistors, enabling automatic and sequential assembly, reducing the risk of coil contact and improving production efficiency by using the connectors as tooling fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ring-shaped varistor is installed after the winding of the coil, then the electromagnetic compatibility is improved, but the production efficiency deteriorates and the process complexity increases
Solution Approach 1:
The ring-shaped varistor is pre-installed on the commutator before the coil winding process. This preliminary action allows the varistor to be in place during winding, eliminating the need for subsequent manual installation and welding operations after the rotor is assembled, thereby significantly improving production efficiency while maintaining electromagnetic compatibility
2Reliability
If the ring-shaped varistor is installed manually after rotor connection, then the electromagnetic compatibility is improved, but the production efficiency deteriorates
Solution Approach 1:
The varistor is pre-mounted on the commutator segments before the rotor is connected to the commutator. This preliminary installation enables automatic welding processes to be used instead of manual installation, dramatically improving production efficiency while ensuring proper electromagnetic compatibility through correct varistor positioning
3Ease of manufacture
If the winding is located between the ring-shaped varistor and the hanging part, then the connection is achieved, but the coil may be accidentally touched reducing motor performance
Solution Approach 1:
The ring-shaped varistor is extracted from the winding area and repositioned on the outer surface of the commutator segments. This separation removes the varistor from the potential hazard zone where it could accidentally contact the coil during manual installation, thereby protecting motor performance while maintaining the electrical connection function through the connector design
Data Source
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AI summary
The present application relates to the technical field of commutator, in particular to a commutator and a production method thereof. The commutator includes a body provided with a wire hanging part, and a connector for mounting an electronic component is arranged on one side of the body far from the wire hanging part. The present application can facilitate optimization of production process, reasonable allocation of production resources, and automatic welding, is not liable to touch the coil by mistake, and can ensure the performance of the micromotor.