CN110649443B - Production process of automobile commutator component - Google Patents
Production process of automobile commutator component Download PDFInfo
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- CN110649443B CN110649443B CN201910817176.9A CN201910817176A CN110649443B CN 110649443 B CN110649443 B CN 110649443B CN 201910817176 A CN201910817176 A CN 201910817176A CN 110649443 B CN110649443 B CN 110649443B
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- commutator
- inner shell
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/06—Manufacture of commutators
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/005—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
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Abstract
The invention discloses a production process of an automobile commutator component, which comprises the following steps of S1: the commutator segment is formed by punching and drawing a round copper wire, when the commutator segment is punched, a first through hole is reserved on one side of the commutator segment, and convex blocks, S2 and mica sheets are arranged on two sides of the commutator segment: select mica sheet raw materials, relate to the auto-parts field. According to the production process of the automobile commutator component, the commutator segments can be well connected with the inner shell through the preset bumps, the prepared inner shell has good ageing resistance, insulation and voltage resistance through the specially-made inner shell raw materials, the prepared inner shell is particularly good in thermosetting property, the prepared inner shell is durable, the normal operation of the commutator is guaranteed, the manufactured commutator is polished and subjected to flaw detection, the qualification rate of the produced commutator is guaranteed, and meanwhile, the commutator production process is simple and feasible, low in production cost and convenient to popularize.
Description
Technical Field
The invention relates to the technical field of automobile accessories, in particular to a production process of an automobile commutator component.
Background
The commutator is a component which is used for current commutation on a direct current motor and an alternating current series motor and can enable the motor to continuously rotate, is commonly called as a commutator, structurally, the commutator is a circular shape formed by a plurality of contact pieces which are respectively connected with each contact on a rotor, two electrodes connected outside are called as electric brushes to be contacted with the contact, only two of the coils are contacted simultaneously, the principle is that after the coil passes through the current, the coil can rotate through attraction and repulsion under the action of the permanent magnet, when it is rotated to balance with the magnet, the original electrified line is separated from the brush than the contact sheet on the corresponding commutator, the electric brush is connected to the contact corresponding to the group of coils generating the driving force, so that the direct current motor rotates continuously, the commutator is an important element in automobile parts and has high performance requirement, and the production process of the commutator has important influence on the performance of the commutator.
According to the existing production process of the automobile commutator component, commutator segments on the produced commutator are not well connected with an inner shell, the produced inner shell is easy to age and has no good insulation and voltage resistance, the thermosetting property of the produced inner shell cannot meet the requirement, the normal operation of the commutator is not well guaranteed, the commutator is easy to damage when in use, flaw detection is not carried out on the manufactured commutator, the qualification rate of the produced commutator cannot be guaranteed, and meanwhile, the existing commutator production process is complex in steps, high in production cost and inconvenient to popularize.
Disclosure of Invention
Technical problem to be solved
Aiming at the defects of the prior art, the invention provides a production process of an automobile commutator component, which solves the problems that the connection between a commutator segment and an inner shell is unstable, various properties of the inner shell can not meet the use requirements, and the qualification rate can not be guaranteed in the existing production process of the automobile commutator component.
(II) technical scheme
Based on the technical problems existing in the background technology, the invention provides a production process of an automobile commutator component, which comprises the following steps:
s1, punching the commutator segment: the commutator segment is formed by binding, pulling and punching a round copper wire, a first through hole is reserved on one side of the commutator segment when the commutator segment is punched, and convex blocks are arranged on two sides of the commutator segment;
s2, manufacturing of mica sheets: selecting a mica sheet raw material, according to the size and the shape of the side face of the commutator bar punched in the step S1, peeling, fixing the thickness, cutting and punching the mica sheet raw material to manufacture a mica sheet for the commutator, wherein the size and the shape of the side face of the commutator are completely the same as those of the side face of the commutator bar, and one side of the mica sheet for the commutator is provided with a second through hole, the size of which is the same as that of the first through hole in the step S1;
s3, assembling the commutator segments and the mica sheets: selecting a flexible steel bar with the same inner side area as the first through-hole and the second through-hole, inserting the commutator segment manufactured in S1 and the commutator mica sheet manufactured in S2 on the flexible steel bar, and welding two ends of the flexible steel bar after inserting to obtain a commutator segment assembly;
s4, preparation of an inner shell material: selecting 10-18 parts of thermosetting resin, 5-14 parts of dimethyl phosphite, 6-14 parts of polypropylene, 3-8 parts of carbon fiber, 6-12 parts of glass fiber, 1-3 parts of antioxidant, 5-12 parts of calcium silicate, 2-4 parts of stabilizer and 3-6 parts of mica powder, and fully stirring the materials to obtain a mixed raw material of an inner shell;
s5, filling of inner shell material: fixing the commutator segment assembly assembled in S3 on an operation table, placing a cylindrical drum in the commutator segment assembly, fixing the cylindrical drum on the operation table, filling the mixed raw materials of the inner shell manufactured in S4 between the commutator segment assembly and the cylindrical drum, and drying the inner shell;
s6, flattening the commutator: grinding the parts protruding from the top and the bottom of the inner shell on the commutator by using a grinding machine, and wiping off powder on the top and the bottom after grinding;
s7, checking and packaging: and carrying out flaw detection on the produced automobile commutator, packaging qualified products and loading the qualified products into a warehouse.
Preferably, the mica sheet raw material in the step S2 is a natural mica sheet, and has the characteristics of no pollution, insulation and good voltage resistance.
Preferably, in step S3, when the commutator segments and the mica sheets for commutator are mounted, the commutator segments and the mica sheets for commutator need to be cross-mounted, that is, every other commutator segment needs to be mounted with one mica sheet for commutator.
Preferably, the thermosetting resin in step S4 is one or more of polyester resin, epoxy resin and phenolic resin, the stabilizer is white lead, and the antioxidant is di-tert-butyl-p-cresol.
Preferably, when the mixed raw material of the inner shell is manufactured in the step S4, the thermosetting resin, the dimethyl phosphite and the polypropylene are firstly added into a mixing stirrer and stirred for 3-5min, the temperature is controlled at 50-100 ℃, and after the stirring is finished, the carbon fiber, the glass fiber, the antioxidant, the calcium silicate, the stabilizer and the mica powder are continuously stirred for 15-20min, and the temperature is controlled at 70-150 ℃, so that the mixed raw material of the inner shell is obtained.
Preferably, in step S7, the flaw detector is used to detect flaws, and the flaw detector is an X-ray flaw detector.
(III) advantageous effects
The invention provides a production process of an automobile commutator component. The method has the following beneficial effects: the production process of the automobile commutator component comprises the following steps of S1 punching of commutator segments: the commutator segment is formed by punching a round copper wire in a rolling and drawing way, and S2 and the manufacturing of the mica sheet are as follows: selecting a mica sheet raw material, and assembling S3, a commutator bar and the mica sheet: selecting a flexible steel strip with the same inner side area as the first penetrating hole and the second penetrating hole, S4, preparing an inner shell material, S5, filling the inner shell material: fixing the assembled commutator segment assembly in the step S3 on an operation table, and grinding the commutator in the step S6: grinding the top and bottom protruding parts of the inner shell on the commutator by using a grinder, S7, checking and packaging: the manufactured automobile commutator is subjected to flaw detection, qualified products are packaged and put into a warehouse, the commutator segments can be well connected with the inner shell through the preset bumps, the prepared inner shell has good ageing resistance, insulation and voltage resistance through specially-made inner shell raw materials, the prepared inner shell is particularly good in thermosetting property, the prepared inner shell is durable, the normal operation of the commutator is guaranteed, the manufactured commutator is polished and subjected to flaw detection, the qualification rate of the manufactured commutator is guaranteed, and meanwhile, the commutator is simple and easy in production process, low in production cost and convenient to popularize.
Drawings
FIG. 1 is a schematic diagram of the structure of the present invention;
FIG. 2 is an enlarged view of a portion of the invention at A in FIG. 1;
FIG. 3 is a statistical table of comparative experimental data according to the present invention.
In the figure, 1-commutator segment, 2-lug and 3-mica sheet for commutator.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-3, the embodiment of the present invention provides three technical solutions: a production process of an automobile commutator component specifically comprises the following embodiments:
example 1
S1, punching the commutator segment: the commutator segment 1 is formed by binding, drawing and punching a round copper wire, when the commutator segment 1 is punched, a first through hole is reserved on one side of the commutator segment 1, and the two sides of the commutator segment 1 are both provided with a convex block 2;
s2, manufacturing of mica sheets: selecting a mica sheet raw material, according to the size and the shape of the side face of the commutator segment 1 punched in the step S1, peeling, fixing the thickness, cutting and punching the mica sheet raw material to manufacture a commutator mica sheet 3 which is completely the same as the size and the shape of the side face of the commutator segment 1, and arranging a second through hole which is the same as the first through hole in the step S1 on one side of the commutator mica sheet 3;
s3, assembling the commutator segments and the mica sheets: selecting a flexible steel bar with the same inner side area as the first through-hole and the second through-hole, inserting the commutator segment 1 manufactured in S1 and the commutator mica sheet 3 manufactured in S2 on the flexible steel bar, and welding two ends of the flexible steel bar after inserting to obtain a commutator segment assembly;
s4, preparation of an inner shell material: selecting 10 parts of thermosetting resin, 5 parts of dimethyl phosphite, 6 parts of polypropylene, 8 parts of carbon fiber, 12 parts of glass fiber, 3 parts of antioxidant, 12 parts of calcium silicate, 4 parts of stabilizer and 6 parts of mica powder, fully stirring the materials to obtain an inner shell mixed raw material, wherein the thermosetting resin is polyester resin, the stabilizer is lead white, and the antioxidant is di-tert-butyl-p-cresol, when the inner shell mixed raw material is prepared, firstly adding the thermosetting resin, the dimethyl phosphite and the polypropylene into a mixing stirrer, stirring the mixture for 3min, controlling the temperature to be 50 ℃, continuing to stir the carbon fiber, the glass fiber, the antioxidant, the calcium silicate, the stabilizer and the mica powder for 15min after the stirring is finished, and controlling the temperature to be 70 ℃ to obtain an inner shell mixed raw material;
s5, filling of inner shell material: fixing the commutator segment assembly assembled in S3 on an operation table, placing a cylindrical drum in the commutator segment assembly, fixing the cylindrical drum on the operation table, filling the mixed raw materials of the inner shell manufactured in S4 between the commutator segment assembly and the cylindrical drum, and drying the inner shell;
s6, flattening the commutator: grinding the parts protruding from the top and the bottom of the inner shell on the commutator by using a grinding machine, and wiping off powder on the top and the bottom after grinding;
s7, checking and packaging: and (3) carrying out flaw detection on the produced automobile commutator, carrying out flaw detection by adopting a flaw detector, wherein the flaw detector is an X-ray flaw detector, and packaging qualified products and putting the qualified products into a warehouse.
Example 2
S1, punching the commutator segment: the commutator segment 1 is formed by binding, drawing and punching a round copper wire, when the commutator segment 1 is punched, a first through hole is reserved on one side of the commutator segment 1, and the two sides of the commutator segment 1 are both provided with a convex block 2;
s2, manufacturing of mica sheets: selecting a mica sheet raw material, according to the size and the shape of the side face of the commutator segment 1 punched in the step S1, peeling, fixing the thickness, cutting and punching the mica sheet raw material to manufacture a commutator mica sheet 3 which is completely the same as the size and the shape of the side face of the commutator segment 1, and arranging a second through hole which is the same as the first through hole in the step S1 on one side of the commutator mica sheet 3;
s3, assembling the commutator segments and the mica sheets: selecting a flexible steel bar with the same inner side area as the first through-hole and the second through-hole, inserting the commutator segment 1 manufactured in S1 and the commutator mica sheet 3 manufactured in S2 on the flexible steel bar, and welding two ends of the flexible steel bar after inserting to obtain a commutator segment assembly;
s4, preparation of an inner shell material: selecting 15 parts of thermosetting resin, 9 parts of dimethyl phosphite, 10 parts of polypropylene, 5 parts of carbon fiber, 9 parts of glass fiber, 2 parts of antioxidant, 8 parts of calcium silicate, 3 parts of stabilizer and 5 parts of mica powder, fully stirring the materials to obtain an inner shell mixed raw material, wherein the thermosetting resin is epoxy resin, the stabilizer is lead white, and the antioxidant is di-tert-butyl-p-cresol;
s5, filling of inner shell material: fixing the commutator segment assembly assembled in S3 on an operation table, placing a cylindrical drum in the commutator segment assembly, fixing the cylindrical drum on the operation table, filling the mixed raw materials of the inner shell manufactured in S4 between the commutator segment assembly and the cylindrical drum, and drying the inner shell;
s6, flattening the commutator: grinding the parts protruding from the top and the bottom of the inner shell on the commutator by using a grinding machine, and wiping off powder on the top and the bottom after grinding;
s7, checking and packaging: and (3) carrying out flaw detection on the produced automobile commutator, carrying out flaw detection by adopting a flaw detector, wherein the flaw detector is an X-ray flaw detector, and packaging qualified products and putting the qualified products into a warehouse.
Example 3
S1, punching the commutator segment: the commutator segment 1 is formed by binding, drawing and punching a round copper wire, when the commutator segment 1 is punched, a first through hole is reserved on one side of the commutator segment 1, and the two sides of the commutator segment 1 are both provided with a convex block 2;
s2, manufacturing of mica sheets: selecting a mica sheet raw material, according to the size and the shape of the side face of the commutator segment 1 punched in the step S1, peeling, fixing the thickness, cutting and punching the mica sheet raw material to manufacture a commutator mica sheet 3 which is completely the same as the size and the shape of the side face of the commutator segment 1, and arranging a second through hole which is the same as the first through hole in the step S1 on one side of the commutator mica sheet 3;
s3, assembling the commutator segments and the mica sheets: selecting a flexible steel bar with the same inner side area as the first through-hole and the second through-hole, inserting the commutator segment 1 manufactured in S1 and the commutator mica sheet 3 manufactured in S2 on the flexible steel bar, and welding two ends of the flexible steel bar after inserting to obtain a commutator segment assembly;
s4, preparation of an inner shell material: selecting 18 parts of thermosetting resin, 14 parts of dimethyl phosphite, 14 parts of polypropylene, 3 parts of carbon fiber, 6-parts of glass fiber, 1 part of antioxidant, 5 parts of calcium silicate, 2 parts of stabilizer and 3 parts of mica powder, fully stirring the materials to obtain an inner shell mixed raw material, wherein the thermosetting resin is phenolic resin, the stabilizer is lead white, and the antioxidant is di-tert-butyl-p-cresol;
s5, filling of inner shell material: fixing the commutator segment assembly assembled in S3 on an operation table, placing a cylindrical drum in the commutator segment assembly, fixing the cylindrical drum on the operation table, filling the mixed raw materials of the inner shell manufactured in S4 between the commutator segment assembly and the cylindrical drum, and drying the inner shell;
s6, flattening the commutator: grinding the parts protruding from the top and the bottom of the inner shell on the commutator by using a grinding machine, and wiping off powder on the top and the bottom after grinding;
s7, checking and packaging: and (3) carrying out flaw detection on the produced automobile commutator, carrying out flaw detection by adopting a flaw detector, wherein the flaw detector is an X-ray flaw detector, and packaging qualified products and putting the qualified products into a warehouse.
Effects of the embodiment
A certain commutator manufacturer respectively adopts the production processes of examples 1-3 and the common production process to produce commutators, each process produces 100 commutators, the experimental statistics shows that the time required for producing 100 commutators in examples 1-3 is 6 hours, the time required for producing 100 commutators in the common production process is 10 hours, in the thermosetting test, the commutator produced in example 1 can withstand a high temperature of 750 ℃, the commutator produced in example 2 can withstand a high temperature of 800 ℃, the commutator produced in example 3 can withstand a high temperature of 780 ℃, the commutator produced in the ordinary production process can withstand a high temperature of 500 ℃, the total cost of the commutator produced in example 1 is 9200 yuan, the total cost of the commutator produced in example 2 is 9000 yuan, the total cost of the commutator produced in example 3 is 9100 yuan, and the total cost of the commutator produced in the ordinary production process is 12000 yuan.
In conclusion, the commutator produced by the production process of the automobile commutator component in the embodiment 2 has the best performance.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (6)
1. The production process of the automobile commutator component is characterized by comprising the following steps:
s1, punching the commutator segment: the commutator segment (1) is formed by punching and drawing a round copper wire, when the commutator segment (1) is punched, a first through hole is reserved on one side of the commutator segment (1), and convex blocks (2) are arranged on two sides of the commutator segment (1);
s2, manufacturing of mica sheets: selecting a mica sheet raw material, according to the size and the shape of the side face of the commutator segment (1) punched in the step S1, peeling, fixing the thickness, cutting and punching to manufacture the mica sheet raw material into a mica sheet (3) for the commutator, wherein the size and the shape of the side face of the commutator segment (1) are completely the same as those of the mica sheet (3), and a second through hole, the size of which is the same as that of the first through hole in the step S1, is formed in one side of the mica sheet (3) for the commutator;
s3, assembling the commutator segments and the mica sheets: selecting a flexible steel bar with the same inner side area as the first through-inserting hole and the second through-inserting hole, inserting the commutator segment (1) manufactured in S1 and the commutator mica sheet (3) manufactured in S2 on the flexible steel bar, and after inserting, welding two ends of the flexible steel bar to obtain a commutator segment assembly;
s4, preparation of an inner shell material: selecting 10-18 parts of thermosetting resin, 5-14 parts of dimethyl phosphite, 6-14 parts of polypropylene, 3-8 parts of carbon fiber, 6-12 parts of glass fiber, 1-3 parts of antioxidant, 5-12 parts of calcium silicate, 2-4 parts of stabilizer and 3-6 parts of mica powder, and fully stirring the materials to obtain a mixed raw material of an inner shell;
s5, filling of inner shell material: fixing the commutator segment assembly assembled in S3 on an operation table, placing a cylindrical drum in the commutator segment assembly, fixing the cylindrical drum on the operation table, filling the mixed raw materials of the inner shell manufactured in S4 between the commutator segment assembly and the cylindrical drum, and drying the inner shell;
s6, flattening the commutator: grinding the parts protruding from the top and the bottom of the inner shell on the commutator by using a grinding machine, and wiping off powder on the top and the bottom after grinding;
s7, checking and packaging: and carrying out flaw detection on the produced automobile commutator, packaging qualified products and loading the qualified products into a warehouse.
2. The process for producing an automobile commutator member according to claim 1, wherein: in the step S2, the mica sheet is made of natural mica sheet, and has the characteristics of no pollution, insulation and good voltage resistance.
3. The process for producing an automobile commutator member according to claim 1, wherein: in the step S3, when the commutator segments (1) and the mica sheets (3) for the commutator are mounted, the commutator segments need to be cross-mounted, that is, every other commutator segment (1) needs to be mounted with a mica sheet (3) for the commutator.
4. The process for producing an automobile commutator member according to claim 1, wherein: the thermosetting resin in the step S4 is one or more of polyester resin, epoxy resin and phenolic resin, the stabilizer is lead white, and the antioxidant is di-tert-butyl-p-cresol.
5. The process for producing an automobile commutator member according to claim 1, wherein: when the mixed raw material of the inner shell is manufactured in the step S4, firstly, the thermosetting resin, the dimethyl phosphite and the polypropylene are added into a mixing stirrer, the stirring is carried out for 3-5min, the temperature is controlled at 50-100 ℃, after the stirring is finished, the carbon fiber, the glass fiber, the antioxidant, the calcium silicate, the stabilizer and the mica powder are continuously stirred for 15-20min, and the temperature is controlled at 70-150 ℃, so that the mixed raw material of the inner shell is obtained.
6. The process for producing an automobile commutator member according to claim 1, wherein: in step S7, a flaw detector is used for flaw detection, and the flaw detector is an X-ray flaw detector.
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101355221A (en) * | 2008-08-29 | 2009-01-28 | 宁波华瑞电器有限公司 | Method for manufacturing hook type commutator |
| CN201528256U (en) * | 2009-09-10 | 2010-07-14 | 迪克斯汽车电器(上海)有限公司 | Commutator of automobile motor |
| CN104158043A (en) * | 2014-08-23 | 2014-11-19 | 范文青 | DC motor commutator and manufacture method thereof, and DC motor |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4283841A (en) * | 1978-01-26 | 1981-08-18 | Mitsuba Electric Mfg. Co., Ltd. | Method of manufacturing a commutator |
| US6242839B1 (en) * | 2000-03-01 | 2001-06-05 | Kirkwood Industries, Inc. | Commutator and method for manufacturing |
| CN101494350A (en) * | 2009-02-25 | 2009-07-29 | 宁波华瑞电器有限公司 | Method for manufacturing commutator |
| CN102810806A (en) * | 2012-08-20 | 2012-12-05 | 瑞安市恒丰机电有限公司 | Reversing sheet, reverser manufactured by reversing sheet and manufacturing process of reverser |
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- 2019-08-30 CN CN201910817176.9A patent/CN110649443B/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101355221A (en) * | 2008-08-29 | 2009-01-28 | 宁波华瑞电器有限公司 | Method for manufacturing hook type commutator |
| CN201528256U (en) * | 2009-09-10 | 2010-07-14 | 迪克斯汽车电器(上海)有限公司 | Commutator of automobile motor |
| CN104158043A (en) * | 2014-08-23 | 2014-11-19 | 范文青 | DC motor commutator and manufacture method thereof, and DC motor |
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Effective date of registration: 20230609 Address after: No. 58, Qianxi West Road, Bailian Village, Pandai Street, Rui'an City, Wenzhou City, Zhejiang Province 325000 Patentee after: Rui'an Walleo Electromechanical Co.,Ltd. Address before: 225003 Fanchuan town science and Technology Park, Jiangdu District, Yangzhou City, Jiangsu Province Patentee before: YANGZHOU HUACHANG AUTO ELECTRICAL Co.,Ltd. |