CN101242067A - Manufacturing method for copper plane converter - Google Patents

Manufacturing method for copper plane converter Download PDF

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Publication number
CN101242067A
CN101242067A CNA2008100841317A CN200810084131A CN101242067A CN 101242067 A CN101242067 A CN 101242067A CN A2008100841317 A CNA2008100841317 A CN A2008100841317A CN 200810084131 A CN200810084131 A CN 200810084131A CN 101242067 A CN101242067 A CN 101242067A
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copper
hook
accurate
manufacture method
plane converter
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CN100563065C (en
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张浩宇
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SHENZHEN KAIZHONG PRECISION TECHNOLOGY Co Ltd
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Abstract

The present invention relates to a method for manufacturing a copper plane commutator, especially to a method which is used for manufacturing the oil pump motor of the vehicle. The manufacturing method comprises the following procedures: executing cold pressing to the molded cylindrical copper blank to obtain the copper casing rough blank, afterwards executing accurate reshaping to the copper casing rough blank, the accurate copper casing is obtained after material removing, executing pressing molding, groove milling and hook bending to the accurate copper casing, and the copper plane commutator of the invention is obtained. In the method of the invention for manufacturing the copper plane commutator, the accurate copper casing is totally completed through a cold pressing technique and an accurate reshaping technique before the technique procedure of the pressing molding, the precision processing procedures of turning, hook milling and the like are not required, therefore the commutator has the advantages of simple technique procedures, saving labor hour and material, high production efficiency, accurate manufactured copper plane commutator, long service lifetime and the like.

Description

The manufacture method of copper plane converter
Technical field
The present invention relates to the manufacture method of copper plane converter, especially relate to a kind of method by cold extruding technique and precision truing technology manufactured copper flat commutator.
Background technology
In traditional handicraft, the manufacture method of flat commutator is a blade inserting, promptly at first wire rod is carried out rolling, drawing, annealing, then this wire rod punching out is become the commutator segment monolithic, through operations such as inserted sheet, injection mo(u)lding, turning and end face, groove milling, polishings, make the flat commutator finished product again.Wherein the inserted sheet operation is to utilize by hand the commutator segment monolithic is embedded in the groove of special slice arranging apparatus by same direction a slice a slice, mica sheet is inserted between each commutator segment, then with tightening up the thing banding again.
In the blade inserting manufacture method of above-mentioned flat commutator, wire rod is carried out rolling, drawing, annealing, and become the commutator segment monolithic to carry out screening, insert complex procedures, loaded down with trivial details such as mica sheet again through slice arranging apparatus this wire rod punching out, production efficiency is low, the cost height.Particularly the inserted sheet operation needs often to make commutator segment and this slice arranging apparatus have the gap through manual operation, when causing turning and end face operation the half-finished circular runout of flat commutator bigger, make the circularity of commutator relatively poor, thereby influenced serviceability.In addition, must be that a slice is milled in a feed when milling mica slot, can not carry out diagonal angle two mica splitting grooves and once carry out groove milling, the commutator segment that its manual commutator of forming is corresponding in twos is not symmetrical on same straight line, thereby cause carbon brush for electric machine when commutation, to produce deviation, and then produce spark, noise increase, cause commutator useful life and motor performance to reduce.
In order to solve the problems referred to above of traditional handicraft, a kind of method of making flat commutator by the cold-stamped method is disclosed among the Chinese patent literature CN1249867, its manufacturing step comprises: after the round copper wire cutting, carry out cold-extruded and be pressed into the commutator blank, after the cleaning with it injection-compression molding, after turning, groove milling, milling hook, last crotch forms.This manufacture method replaces inserted sheet technology in the conventional method with cold-extrusion technology, simplified production technology, production efficiency is improved, yet because it still needs to carry out turning, mills fine finishining step such as hook behind cold extrusion, injection-compression molding, therefore still exist technology loaded down with trivial details, inefficient problem.
A kind of manufacture method of flat commutator is also disclosed for the problems referred to above Chinese patent literature CN1595734 that solves traditional handicraft, its processing step comprises: getting the circular copper rod that required commutator brush track diameter is more or less the same is the cylindrical, copper base, cold-extruded is pressed into whole round barrel shape copper base, its tubbiness inwall has the quantity convex tendon bar identical with the commutator hook, the bottom has the lifting-hook bar, further turning, punching, trimming, the crotch shaping is machined to barrel wall becomes alternate convex tendon bar, the bottom becomes the tool centre bore, the hook pin that the lifting-hook bar tilts, clean the back injection-compression molding, promptly inject insulating resin injection mo(u)lding shaping again at the tubbiness inner chamber, and copper base bottom split groove milling disc at the bottom of the five equilibrium as required, and be washed till the insulating barrier depths, convex tendon bar crotch is become the commutator hook portion.This manufacture method replaces inserted sheet technology in the conventional method with cold-extrusion technology, simplified production technology to a certain extent, yet it also needs to carry out fine finishining steps such as turning, punching, trimming, curved lifting-hook bar after cold extrusion, therefore still exist technology loaded down with trivial details, inefficient problem.
Chinese patent literature CN1546279 discloses the manufacture method of a kind of plane hook-type commutator, comprise base, cold extrusion, injection-compression molding, crotch, operations such as groove milling, the advantage of this technology molds the whole copper shell of plane configuration commutator that a kind of pawl separates for adopting cold extruding technique, yet, the shortcoming of its existence is the requirement height to blank, need be with " packing ring shape blank " with central axis hole (referring to first page the 6th section in specification and Figure of description 1), that is to say if raw material is copper coin then needs it is carried out punching press or cutting obtaining central axis hole, otherwise just can only do raw material with copper pipe; In addition, this patent documentation is not disclosed as the forming method of the hook that strengthens the bonding strength between copper commutator segment and supporter.
Summary of the invention
For this reason, technical problem to be solved by this invention is to propose the manufacture method that a kind of processing step is saved man-hour and material, copper plane converter that production efficiency is higher simply, more.
It is accurate that another technical problem to be solved by this invention is to propose a kind of size, long service life and do not need to carry out the manufacture method of accurately machined copper plane converter.
For solving the problems of the technologies described above, the manufacture method of copper plane converter of the present invention may further comprise the steps:
(a) the cylindrical, copper base cold-extruded with forming is pressed into whole copper shell crude green body, makes described copper shell crude green body have semi-enclosed cavity, makes described cavity be the openend of outside opening and the working end with a central axis hole relative with openend;
(b) described copper shell crude green body is carried out obtaining behind precision truing and the blanking having at described openend the accurate copper shell of a plurality of separate sheet pawls, or, carry out the accurate copper shell that precision truing obtains having at described openend a plurality of separate sheet pawls again to described copper shell crude green body elder generation blanking;
(c) described accurate copper shell promptly obtains copper plane converter through injection-compression molding and reprocessing.
Described cold extrusion in the described step (a) is disposable cold extrusion.
Cylindrical, copper base in the described step (a) is solid.
Described reprocessing in the described step (c) is groove milling and crotch, the order interchangeable of groove milling and crotch step wherein, described groove milling step is divided into a plurality of copper commutator segments with described accurate copper shell, and described crotch step curves described pawl the butt hook of described copper plane converter.
Working end at described copper shell crude green body has a plurality of lifting-hook bars on the interior resonator end surface of described openend.
The circumferencial direction of described a plurality of lifting-hook bar described central axis hole in resonator end surface upper edge in described evenly distributes.
Also have a plurality of boss on the resonator end surface in the described copper shell crude green body.
At least has a described lifting-hook bar on each described copper commutator segment.
Described precision truing also comprises the lifting-hook bar of described copper shell crude green body and boss is shaped as the interior hook with branch fork structure of described accurate copper shell and the outer hook that tilts to axis direction respectively.
The interior hook that forms by described lifting-hook bar and match by the outer hook that described boss forms and to form in opposite directions " eight " font structure.
Described precision truing is also realized by the cold extrusion mode.
Technique scheme of the present invention compared with prior art has the following advantages: in the manufacture method of (1) copper plane converter of the present invention, accurate copper shell is all finished by cold extruding technique and accurate integer technology before the shaping process of pressure injection step, promptly after the shaping process of pressure injection step, no longer need it is carried out turning, mills fine finishining steps such as hook, therefore compared with prior art, use method of the present invention can not destroy the matrix of the thermosets of formation, make that the copper plane converter that makes is accurate more, the useful life of further having improved product; (2) similarly, the present invention is because after cold extrusion, precision truing and shaping process of pressure injection step, do not need to carry out turning again, mill fine finishining steps such as hook, therefore be a kind of method of pass through cold extruding technique manufactured copper flat commutator truly, the copper plane converter of being produced has that size is accurate, any surface finish, good reliability, save material, advantages such as productivity ratio height, environmental protection; (3) manufacture method of copper plane converter of the present invention owing to do not need to carry out turning, mill fine finishining step such as hook, has therefore reduced man-hour and production process, is very suitable for industrialized mass; (4) making the used raw material of copper plane converter of the present invention is the cylindrical, copper base of forming, compared with prior art do not need to obtain having by special punch steps in advance " the packing ring shape blank " of central axis hole, the raw material of the inventive method also can be annular copper base, original shape to raw material requires low, have or not central axis hole in the cold extrusion step, to press the copper shell crude green body that obtains having central axis hole by once cold extrusion, therefore further simplified technology and saved production cost, and because low to the original shape requirement of raw material, applicability is stronger.
Description of drawings
For the easier quilt of content of the present invention is clearly understood, below according to a particular embodiment of the invention and in conjunction with the accompanying drawings, the present invention is further detailed explanation.At first accompanying drawing is carried out brief description, wherein:
Fig. 1 is the shape figure of the cylindrical, copper base of embodiment of the invention forming;
Fig. 2 is the schematic diagram of the copper shell crude green body of the embodiment of the invention;
Fig. 3 is that the A-A of Fig. 2 is to cutaway view;
Fig. 4 is the profile of the accurate copper shell of the embodiment of the invention;
Fig. 5 is the vertical view of copper plane converter of the present invention;
Fig. 6 is that the A-A of Fig. 5 is to cutaway view.
Reference numeral is respectively shown in the figure: hook, the outer hook of 15-, 31-cavity, 32-openend, 34-working end, the interior resonator end surface of 35-, 41-sheet pawl in 1-cylindrical, copper base, 2-copper plane converter, 3-copper shell crude green body, the accurate copper shell of 4-, 5-boss, 6-lifting-hook bar, 7-butt hook, 8-contact-segment, 9-copper shell wall, 10-central axis hole, 11-copper commutator segment, 12-supporter, 13-insulation tank, the 14-.
Embodiment
The end face of the copper plane converter described in the present invention is meant the one side of copper plane converter 2 towards brush, and the one side relative with the commutator end face is called the supporter end face.
Fig. 5 and Fig. 6 are the structural representations of an embodiment of copper plane converter of the present invention, it comprises that the uniform ring of a plurality of size shape homogeneous is around in commutator central axis hole 10 and perpendicular to the copper commutator segment 11 of central axis hole 10, a supporter 12 of making by phenolic moulding powder, there is an insulation tank 13 radially between adjacent commutator segment, guarantees non-conductive connection between commutator segment.Wherein, copper commutator segment 11 comprises and being used for and contacted contact-segment 8 of brush and the butt hook 7 that is used to be connected winding.As shown in Figure 6, has deeply hook 15 to interior hook 14 of supporter inside and at each copper commutator segment towards a side of described supporter end face, hook 14 and outer hook 15 complement each other to form " eight " font structure of opposite tilt in described, wherein interior hook 14 is " Y " type branch fork structure, such structure can strengthen the contact strength between commutator segment and supporter, to guarantee described copper plane converter the situation of film flying or film dancing takes place at the Shi Buhui that runs up.
Copper plane converter shown in Figure 5 comprises 8 copper commutator segments 11, and the number of commutator segment can increase and decrease as the case may be in the actual production, as 7 or 10.In addition, the shape of interior hook 14 and outer hook 15 can change according to actual conditions shown in Fig. 6, as being other forked type structure, as long as can play the effect that strengthens the contact strength between commutator segment and supporter.
Below introduce the manufacture method of copper plane converter of the present invention in detail.
Figure 1 shows that the shape figure of the cylindrical, copper base 1 of embodiment of the invention forming, the cylindrical, copper base 1 of described forming is the solid cylindrical copper base that obtains by with the blanking of circular copper rod stamping-out or sawing.
The manufacture method of copper plane converter 2 of the present invention is:
(1) earlier described cylindrical, copper base 1 is placed on the cold extrusion press that mould is installed, disposable direct forward extrusion goes out whole copper shell crude green body 3 (referring to Fig. 2 and Fig. 3), described copper shell crude green body 3 is a semi-enclosed cavity 31, comprise the openend 32 that makes described cavity 31 be outside opening, the working end with a central axis hole 10 34 relative with openend 32, and the copper shell wall 9 of connection opening end 32 and working end 34.Working end 34 at described copper shell crude green body 3 has a plurality of boss 5 and lifting-hook bar 6 on the interior resonator end surface 35 of described openend 32, described a plurality of boss 5 and lifting-hook bar 6 evenly distribute along the inwall of described copper shell wall 9 and the circumferencial direction of central axis hole 10 respectively on the resonator end surface 35 in described, wherein, has a described lifting-hook bar 6 at least on each described copper commutator segment 11.
(2) described copper shell crude green body 3 is carried out precision truing, behind blanking, promptly obtain accurate copper shell 4 (referring to Fig. 4), described accurate copper shell 4 place different with copper shell crude green body 3 structures is, the described openend 32 of accurate copper shell 4 has a plurality of separate sheet pawls 41 behind blanking, lifting-hook bar 6 in the described copper shell crude green body 3 and boss 5 are shaped as the interior hook 14 with " Y " type branch fork structure of described accurate copper shell 4 and the outer hook 15 that tilts to axis direction respectively by precision truing, and " eight " font structure that hook 14 and outer hook 15 match and formed opposite tilt in described.
(3) in the cavity volume of accurate copper shell 4, insert phenolic moulding powder, be placed on and carry out injection-compression molding on the press injector, described injection-compression molding makes thermosetting phenolic moulding powder and accurate copper shell 4 agglomerated together, copper shell with these moulding product carries out groove milling then, after groove milling is finished, the sheet pawl 41 that will be positioned at accurate copper shell 4 outsides carries out crotch and obtains butt hook 7, promptly makes copper plane converter 2 of the present invention, referring to Fig. 5 and Fig. 6.
Certainly, in a further embodiment, described copper base 1 also can be for having the annular copper base of mesopore, for example copper pipe or copper ring.
In the above-mentioned steps (1), the quantity of boss 5 and lifting-hook bar 6 also can increase and decrease according to actual conditions, and boss 5 can certainly be set.
In step (2), described precision truing is meant by cold extruding technique the circularity of described copper shell crude product 3 is adjusted, thereby improve its serviceability, in described precision truing step, also realized the lifting-hook bar 6 in the described copper shell crude green body 3 is shaped as the interior hook 14 with branch fork structure of described accurate copper shell 4 and the boss 5 in the described copper shell crude green body 3 is shaped as the outer hook 15 that tilts to axis direction of described accurate copper shell 4, and " eight " font structure that hook 14 and outer hook 15 are opposite tilt in above-mentioned.Interior hook 14 by precision truing method of the present invention moulding and outer hook 15 are owing to being by cold extrusion shaped, the institutional framework densification, and because not through machine cut processing, the good integrity of structure, can strengthen the contact strength between commutator segment and supporter, the situation of film flying or film dancing take place at the Shi Buhui that runs up to guarantee described copper plane converter.In addition, in this step, also can described copper shell crude green body 3 first blankings be carried out precision truing to it again and obtain accurate copper shell 4.
In step (3), behind described accurate copper shell 4 injection-compression moldings, also can earlier the sheet pawl 41 that is positioned at the openend 32 of accurate copper shell 4 be carried out crotch and obtain butt hook 7, and then to its groove milling to obtain copper plane converter of the present invention.
In the manufacture method of copper plane converter of the present invention, accurate copper shell is all finished by cold extruding technique and accurate integer technology before the shaping process of pressure injection step, promptly after the shaping process of pressure injection step, no longer need it is carried out turning, mills fine finishining steps such as hook, therefore compared with prior art, use method of the present invention can not destroy the matrix of the thermosets of formation, make that the copper plane converter that makes is accurate more, the useful life of further having improved product.
Similarly, the present invention is because after cold extrusion, precision truing and shaping process of pressure injection step, do not need to carry out turning again, mill fine finishining steps such as hook, therefore be a kind of method of pass through cold extruding technique manufactured copper flat commutator truly, the copper plane converter of being produced has that size is accurate, any surface finish, good reliability, save material, advantages such as productivity ratio height, environmental protection.
In addition, the manufacture method of copper plane converter of the present invention owing to do not need to carry out turning, mill fine finishining step such as hook, has therefore reduced man-hour and production process, is very suitable for industrialized mass.
Making the used raw material of copper plane converter of the present invention is the cylindrical, copper base of forming, compared with prior art do not need to obtain having by special punch steps in advance " the packing ring shape blank " of central axis hole, the raw material of the inventive method also can be annular copper base, original shape to raw material requires low, have or not central axis hole in the cold extrusion step, to press the copper shell crude green body that obtains having central axis hole by once cold extrusion, therefore further simplified technology and saved production cost, and because low to the original shape requirement of raw material, applicability is stronger.
Obviously, the foregoing description only is for example clearly is described, and is not the qualification to execution mode.For those of ordinary skill in the field, can also make other changes in different forms on the basis of the above description.Here need not also can't give exhaustive to all execution modes.And conspicuous variation of being extended out thus or change still are among the protection range of the invention.

Claims (10)

1. the manufacture method of a copper plane converter is characterized in that said method comprising the steps of:
(a) cylindrical, copper base (1) cold-extruded with forming is pressed into whole copper shell crude green body (3), makes described copper shell crude green body (3) have semi-enclosed cavity (31), makes described cavity (31) be the openend (32) of outside opening and the working end (34) with a central axis hole (10) relative with openend (32);
(b) described copper shell crude green body (3) is carried out obtaining behind precision truing and the blanking having at described openend (32) the accurate copper shell (4) of a plurality of separate sheet pawls (41), or, carry out the accurate copper shell (4) that precision truing obtains having at described openend (32) a plurality of separate sheet pawls (41) again to the first blanking of described copper shell crude green body (3);
(c) described accurate copper shell (4) promptly obtains copper plane converter (2) through injection-compression molding and reprocessing.
2. the manufacture method of copper plane converter according to claim 1, it is characterized in that: the described cold extrusion in the described step (a) is disposable cold extrusion.
3. the manufacture method of copper plane converter according to claim 2, it is characterized in that: the cylindrical, copper base (1) in the described step (a) is solid.
4. the manufacture method of copper plane converter according to claim 3, it is characterized in that: the described reprocessing in the described step (c) is groove milling and crotch, the order interchangeable of groove milling and crotch step wherein, described groove milling step is divided into a plurality of copper commutator segments (11) with described accurate copper shell (4), and described crotch step curves described pawl (41) butt hook (7) of described copper plane converter (2).
5. the manufacture method of copper plane converter according to claim 4, it is characterized in that: the working end (34) at described copper shell crude green body (3) has a plurality of lifting-hook bars (6) and boss (5) on the interior resonator end surface (35) of described openend (32).
6. the manufacture method of copper plane converter according to claim 5, it is characterized in that: the circumferencial direction of described a plurality of lifting-hook bars (6) described central axis hole in resonator end surface (35) upper edge (10) in described evenly distributes.
7. the manufacture method of copper plane converter according to claim 6 is characterized in that: have a described lifting-hook bar (6) at least on each described copper commutator segment (11).
8. according to the manufacture method of any described copper plane converter among the claim 1-7, it is characterized in that: described precision truing also comprises the lifting-hook bar (6) of described copper shell crude green body (3) and boss (5) is shaped as the interior hook (14) with branch fork structure of described accurate copper shell (4) and the outer hook (15) that tilts to axis direction respectively.
9. the manufacture method of copper plane converter according to claim 8 is characterized in that: the interior hook (14) that is formed by described lifting-hook bar (6) and matched by the outer hook (15) that described boss (5) forms and to form in opposite directions " eight " font structure.
10. the manufacture method of copper plane converter according to claim 9, it is characterized in that: described precision truing is also realized by the cold extrusion mode.
CNB2008100841317A 2008-03-26 2008-03-26 The manufacture method of copper plane converter Active CN100563065C (en)

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102332669A (en) * 2010-07-12 2012-01-25 德昌电机(深圳)有限公司 Commutator and production method thereof
CN102544960A (en) * 2012-02-21 2012-07-04 瑞安市博宇电器有限公司 Special commutator for car starting motor
CN103151673A (en) * 2013-03-29 2013-06-12 浙江利丰电器股份有限公司 Machining method for commutator
CN105938971A (en) * 2016-06-24 2016-09-14 吴清照 Commutator manufacture process
CN108767611A (en) * 2018-06-06 2018-11-06 深圳市凯中精密技术股份有限公司 A method of producing copper shell for the material-strap structure of commutator processing and using it
CN111965501A (en) * 2020-09-11 2020-11-20 哈尔滨电气动力装备有限公司 Commutator insulating ring material verification process

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102332669A (en) * 2010-07-12 2012-01-25 德昌电机(深圳)有限公司 Commutator and production method thereof
CN102332669B (en) * 2010-07-12 2015-08-19 德昌电机(深圳)有限公司 Commutator and its preparation method
CN102544960A (en) * 2012-02-21 2012-07-04 瑞安市博宇电器有限公司 Special commutator for car starting motor
CN103151673A (en) * 2013-03-29 2013-06-12 浙江利丰电器股份有限公司 Machining method for commutator
CN105938971A (en) * 2016-06-24 2016-09-14 吴清照 Commutator manufacture process
CN105938971B (en) * 2016-06-24 2018-01-30 吴清照 Commutator manufacture craft
CN108767611A (en) * 2018-06-06 2018-11-06 深圳市凯中精密技术股份有限公司 A method of producing copper shell for the material-strap structure of commutator processing and using it
CN108767611B (en) * 2018-06-06 2024-04-26 深圳市凯中精密技术股份有限公司 Material belt structure for processing commutator and method for producing copper shell by using material belt structure
CN111965501A (en) * 2020-09-11 2020-11-20 哈尔滨电气动力装备有限公司 Commutator insulating ring material verification process

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