阅读说明：本技术 一种微型有刷电机转子绕组整形模具及其使用方法 (Miniature brush motor rotor winding shaping die and use method thereof ) 是由 张青青 郭路宝 李立杰 马爱霞 黄非非 陈文博 王宪云 于 2021-01-08 设计创作，主要内容包括：本发明涉及一种微型有刷电机转子绕组整形模具及其使用方法,模具包括上芯套、下芯套、外套筒、上压块和下压块；上芯套下端和下芯套上端分别设有环形插槽,分别与转子轴套上端部和下端部插装配合,上芯套外环面和下芯套外环面形成绕组内限位面；外套筒同心套设于转子轴套的外部,外套筒内环面形成绕组外限位面；上压块由上至下压装于上芯套外环面与外套筒内环面之间,上压块下端面与待整形绕组上端接触；下压块由下至上压装于下芯套外环面与外套筒内环面之间,下压块上端面与待整形绕组下端接触；在上压块下压至上限位台面与外套筒上端接触,下压块上压至下限位台面与外套筒下端接触,使中心压绕组达到特定尺寸。本发明避免了过整形及整形不到位。(The invention relates to a micro brush motor rotor winding shaping die and a using method thereof, wherein the die comprises an upper core sleeve, a lower core sleeve, an outer sleeve, an upper pressing block and a lower pressing block; the lower end of the upper core sleeve and the upper end of the lower core sleeve are respectively provided with an annular slot which is respectively matched with the upper end part and the lower end part of the rotor shaft sleeve in an inserting way, and the outer ring surface of the upper core sleeve and the outer ring surface of the lower core sleeve form a winding inner limiting surface; the outer sleeve is concentrically sleeved outside the rotor shaft sleeve, and the inner ring surface of the outer sleeve forms a winding outer limiting surface; the upper pressing block is pressed between the outer ring surface of the upper core sleeve and the inner ring surface of the outer sleeve from top to bottom, and the lower end surface of the upper pressing block is contacted with the upper end of the winding to be shaped; the lower pressing block is pressed between the outer ring surface of the lower core sleeve and the inner ring surface of the outer sleeve from bottom to top, and the upper end surface of the lower pressing block is in contact with the lower end of the winding to be shaped; the upper pressing block is pressed downwards until the upper limiting table surface is contacted with the upper end of the outer sleeve, and the lower pressing block is pressed upwards until the lower limiting table surface is contacted with the lower end of the outer sleeve, so that the central pressing coil reaches a specific size. The invention avoids over-shaping and incomplete shaping.)

1. The utility model provides a miniature brush motor rotor winding plastic mould which characterized in that: comprises an upper core sleeve, a lower core sleeve, an outer sleeve, an upper pressing block and a lower pressing block;

the lower end of the upper core sleeve and the upper end of the lower core sleeve are respectively provided with an annular slot which is respectively in inserting fit with the upper end part and the lower end part of the rotor shaft sleeve, and the outer ring surface of the upper core sleeve and the outer ring surface of the lower core sleeve form a winding inner limiting surface; bolt penetrating holes are formed in the center of the upper core sleeve and the center of the lower core sleeve, and the upper core sleeve and the lower core sleeve are fixedly connected with the rotor shaft sleeve in the axial direction through penetrating fastening bolts;

the outer sleeve is concentrically sleeved outside the rotor shaft sleeve, the inner ring surface of the outer sleeve forms a winding outer limiting surface, and a winding shaping space is formed between the winding inner limiting surface and the winding outer limiting surface;

the upper pressing block and the lower pressing block are annular pressing blocks, an upper limiting table surface and a lower limiting table surface are respectively arranged on the upper pressing block and the lower pressing block, the upper pressing block is pressed in an annular space between the outer ring surface of the upper core sleeve and the inner ring surface of the outer sleeve from top to bottom, and the lower end surface of the upper pressing block is in contact with the upper end of the winding to be shaped; the lower pressing block is pressed in an annular space between the outer ring surface of the lower core sleeve and the inner ring surface of the outer sleeve from bottom to top, and the upper end surface of the lower pressing block is in contact with the lower end of the winding to be shaped; the upper pressing block is pressed downwards until the upper limiting table surface is contacted with the upper end of the outer sleeve, and the lower pressing block is pressed upwards until the lower limiting table surface is contacted with the lower end of the outer sleeve, so that the central pressing coil reaches a specific size.

2. The use method of the rotor winding shaping die of the miniature brushed motor according to claim 1, comprising the following steps:

step 1, an upper core sleeve and a lower core sleeve are sleeved in a rotor shaft sleeve and are respectively assembled with the upper end part and the lower end part of the rotor shaft sleeve in an inserting way;

step 2, a bolt penetrates through a bolt penetrating hole of the upper core sleeve, a central hole of the rotor shaft sleeve and a bolt penetrating hole of the lower core sleeve, and a nut is screwed on the bolt, so that the upper core sleeve and the lower core sleeve are fixedly connected with the rotor shaft sleeve along the axial direction;

step 3, the commutator end surface in the rotor winding faces upwards, and the commutator end surface is arranged into the outer sleeve from bottom to top;

step 4, respectively filling the upper pressing block and the lower pressing block into a space between the upper core sleeve and the outer sleeve and a space between the lower core sleeve and the outer sleeve;

step 5, on the hydraulic press, pressing the upper pressing block to the upper limit table surface to be contacted with the upper end of the outer sleeve, and simultaneously pressing the lower pressing block to the lower limit end surface to be contacted with the lower end of the outer sleeve;

and 6, removing the upper pressing block, the lower pressing block, the outer sleeve, the upper core shaft and the lower core shaft, and taking out the motor rotor.

Technical Field

The invention belongs to the field of torque motor assembly, and particularly relates to a micro brush motor rotor winding shaping die and a use method thereof.

Background

The motor rotor winding is an important component of the motor, and the winding 102 is matched with the rotor iron core 104 to form a regular magnetic field in the presence of current, so that the special function of the motor is realized. The brush direct current torque motor is an important component of the motor, and the micro brush motor occupies an important position in the micro special motor, so that the special purpose of the micro brush motor is provided for many fields. The medium-large motor has larger size and has not strict requirements on the space size of each component. The overall size of the micro motor is small, and the design size of the whole motor is strictly limited, so that the space requirements of all components are stricter, and the spare space size does not exist basically. The rotor winding is formed by winding an enameled wire, a large margin space is formed in the wound coil, and the space of the wound coil needs to be fully utilized to realize the performance of the whole set of motor. Therefore, the winding needs to be shaped, and the inner space is occupied. However, due to the small size of the micro motor and the thin enameled wire, the enameled wire is very easy to be damaged in the winding shaping process, so that the yield is reduced or the motor has hidden quality troubles, and even the motor cannot be manufactured

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provides a miniature brush motor rotor winding shaping die and a using method thereof, and the miniature brush motor rotor winding shaping die can avoid the situation that an enameled wire is damaged due to the fact that the size is not in place or the shaping is excessive during the winding shaping.

The above object of the present invention is achieved by the following technical solutions:

the utility model provides a miniature brush motor rotor winding plastic mould which characterized in that: comprises an upper core sleeve, a lower core sleeve, an outer sleeve, an upper pressing block and a lower pressing block;

the lower end of the upper core sleeve and the upper end of the lower core sleeve are respectively provided with an annular slot which is respectively in inserting fit with the upper end part and the lower end part of the rotor shaft sleeve, and the outer ring surface of the upper core sleeve and the outer ring surface of the lower core sleeve form a winding inner limiting surface; bolt penetrating holes are formed in the center of the upper core sleeve and the center of the lower core sleeve, and the upper core sleeve and the lower core sleeve are fixedly connected with the rotor shaft sleeve in the axial direction through penetrating fastening bolts;

the outer sleeve is concentrically sleeved outside the rotor shaft sleeve, the inner ring surface of the outer sleeve forms a winding outer limiting surface, and a winding shaping space is formed between the winding inner limiting surface and the winding outer limiting surface;

the upper pressing block and the lower pressing block are annular pressing blocks, an upper limiting table surface and a lower limiting table surface are respectively arranged on the upper pressing block and the lower pressing block, the upper pressing block is pressed in an annular space between the outer ring surface of the upper core sleeve and the inner ring surface of the outer sleeve from top to bottom, and the lower end surface of the upper pressing block is in contact with the upper end of the winding to be shaped; the lower pressing block is pressed in an annular space between the outer ring surface of the lower core sleeve and the inner ring surface of the outer sleeve from bottom to top, and the upper end surface of the lower pressing block is in contact with the lower end of the winding to be shaped; the upper pressing block is pressed downwards until the upper limiting table surface is contacted with the upper end of the outer sleeve, and the lower pressing block is pressed upwards until the lower limiting table surface is contacted with the lower end of the outer sleeve, so that the central pressing coil reaches a specific size.

The use method of the shaping die for the rotor winding of the miniature brush motor is characterized by comprising the following steps of: based on above-mentioned miniature brush motor rotor winding plastic mould, including the following step:

step 1, an upper core sleeve and a lower core sleeve are sleeved in a rotor shaft sleeve and are respectively assembled with the upper end part and the lower end part of the rotor shaft sleeve in an inserting way;

step 2, a bolt penetrates through a bolt penetrating hole of the upper core sleeve, a central hole of the rotor shaft sleeve and a bolt penetrating hole of the lower core sleeve, and a nut is screwed on the bolt, so that the upper core sleeve and the lower core sleeve are fixedly connected with the rotor shaft sleeve along the axial direction;

step 3, the commutator end surface in the rotor winding faces upwards, and the commutator end surface is arranged into the outer sleeve from bottom to top;

step 4, respectively filling the upper pressing block and the lower pressing block into a space between the upper core sleeve and the outer sleeve and a space between the lower core sleeve and the outer sleeve;

step 5, on the hydraulic press, pressing the upper pressing block to the upper limit table surface to be contacted with the upper end of the outer sleeve, and simultaneously pressing the lower pressing block to the lower limit end surface to be contacted with the lower end of the outer sleeve;

and 6, removing the upper pressing block, the lower pressing block, the outer sleeve, the upper core shaft and the lower core shaft, and taking out the motor rotor.

The invention has the advantages and positive effects that:

1. the rotor winding shaping device adopts the upper core sleeve and the lower core sleeve to be coaxially and fixedly connected with the rotor shaft barrel, the size limitation of the shaping inner ring of the rotor winding is realized through the outer ring surfaces of the two core sleeves, and the size limitation of the shaping outer ring of the rotor winding is realized through the inner ring surface of the outer sleeve by adopting the outer sleeve.

2. According to the invention, the upper and lower pressing blocks are adopted to apply shaping acting force on the rotor winding, and after the upper limiting table surface and the lower limiting table surface are respectively contacted with the upper end surface of the outer sleeve and the lower end surface of the outer sleeve, shaping in place limitation is realized, over-shaping and non-shaping are avoided, the in-place shaping size is ensured to be consistent with the design size, and the qualified rate of products reaches one hundred percent.

Drawings

FIG. 1 is a block diagram of a brush motor rotor;

FIG. 2 is a cross-sectional view of the motor rotor installed into a winding form;

fig. 3 is an overall configuration view of the winding shaping mold.

Detailed Description

The present invention will be described in further detail with reference to the following embodiments, which are illustrative only and not limiting, and the scope of the present invention is not limited thereby.

The invention provides a miniature brush motor rotor winding shaping die which is scientific and reasonable in design and does not damage enameled wires and a using method thereof.

The technical scheme adopted by the invention is as follows:

through the compression coefficient of control enameled wire, the size after the adjustment winding plastic avoids excessively compressing tightly to cause the enameled wire damage on the one hand, and on the other hand avoids the too big influence motor of winding size to use. The invention designs a winding shaping die, which controls the compression coefficient, limits the shaped space and realizes the shaping of a winding.

And setting a coefficient zeta for the winding shaping compaction degree, wherein the coefficient represents the compaction condition of the winding. Theoretically calculating occupied volume S of winding enameled wire₁Actual winding occupation volume S₂。

The relationship between the three values is:

S₁the calculation can be carried out according to the wire diameter and the number of turns of the motor winding, and the calculation is a fixed value. S₂Is the target to be achieved after the winding has been shaped, and this value affects the size of the shaped winding. ζ is the packing factor of the shaping. The smaller zeta represents the larger space between the enameled wires in the winding, the smaller the compaction between the enameled wires is, and the smaller the damage is; the larger zeta represents the smaller space between the enameled wires in the winding, the larger the compaction between the enameled wires is, and the enameled wires can be damaged.

The maximum value of the compression coefficient ζ is different for enamel wires of different shapes (e.g., round, flat). When the enameled wires are round, each enameled wire is arranged most closely, and the theoretical calculation value of zeta isWhen the enameled wires are flat, each enameled wire is arranged most closely, and the theoretical calculation value of zeta is 1. The winding is in a relaxed state at first, and the relaxed enameled wire is extruded into a specific space by adopting a compacting and shaping method, so that the theoretical maximum value of zeta cannot be reached in the actual shaping process, otherwise, the enameled wire is seriously damaged.

From the above analysis, it is found that smaller ζ causes less damage to the winding, and smaller ζ facilitates processing from a processing perspective. However, the size of the micro motor is limited, and the performance of the motor needs to be realized in a smaller space, and the larger the motor design angle ζ is, the smaller the size is. It can be seen that the two are contrary. So ζ is not exactly the same in different motors. Generally, the shaping causes no damage to the enameled wire when the zeta is in the range of 0.2-0.5. However, ζ requires further calculations and validation in order to arrive at a particular motor.

When the motor is applied, the sizes of the inner circle and the outer circle of the winding are limited according to the actual size requirement of the motor. And then, making a compression mold in the axial direction of the winding by referring to the compression coefficient zeta. And in order to avoid excessive compression of the winding, a size limiting module is made. A scientific and reasonable miniature motor winding plastic mould is as follows:

limiting core sleeves, namely an upper core sleeve 2 and a lower core sleeve 4, are respectively arranged inside the windings at the two ends, so that the windings are prevented from exceeding the size inwards in the shaping process; an outer sleeve 3 is arranged on the outer side of the winding to avoid the outward exceeding size of the winding during shaping; two ends of the winding are respectively provided with a pressing block, namely an upper pressing block 1 and a lower pressing block 5, and the winding is pressed towards the center to reach a specific size. In the process, the outer sleeve is used as a size limiting module, so that the pressing block stops extruding the winding when contacting the outer sleeve during pressing.

The using method of the micro motor winding shaping die comprises the following steps:

step 1, an upper core sleeve and a lower core sleeve are sleeved in a rotor shaft sleeve 101 and are respectively assembled with the upper end part and the lower end part of the rotor shaft sleeve in an inserting way;

step 2, a bolt 6 penetrates through a bolt penetrating hole of the upper core sleeve, a central hole of the rotor shaft sleeve and a bolt penetrating hole of the lower core sleeve, and a nut 7 is screwed on the bolt, so that the upper core sleeve and the lower core sleeve are fixedly connected with the rotor shaft sleeve along the axial direction;

step 3, the commutator 103 in the rotor winding is arranged into the outer sleeve from bottom to top in the upward direction;

step 4, respectively filling the upper pressing block and the lower pressing block into a space between the upper core sleeve and the outer sleeve and a space between the lower core sleeve and the outer sleeve;

step 5, on the hydraulic press, pressing the upper pressing block to the upper limit table surface 1.1 to be contacted with the upper end of the outer sleeve, and simultaneously pressing the lower pressing block to the lower limit end surface 5.1 to be contacted with the lower end of the outer sleeve;

and 6, removing the upper pressing block, the lower pressing block, the outer sleeve, the upper core shaft and the lower core shaft, and taking out the motor rotor.

In conclusion, the compression coefficient zeta is reasonably designed, so that the winding can be prevented from being damaged during shaping; the invention is suitable for the miniature brush motor with more strict space requirements, and the shaping yield is close to one hundred percent.

Although the embodiments of the present invention and the accompanying drawings are disclosed for illustrative purposes, those skilled in the art will appreciate that: various substitutions, changes and modifications are possible without departing from the spirit and scope of the invention and the appended claims, and therefore the scope of the invention is not limited to the disclosure of the embodiments and the accompanying drawings.