CN1988326B

CN1988326B - Electric rotary machine, armature, method of manufacturing electric rotary machine and machine for forming armature

Info

Publication number: CN1988326B
Application number: CN2006101637845A
Authority: CN
Inventors: 鬼头和行; 伊藤彰康; 井上胜信; 酒井荣治; 福井实
Original assignee: Denso Corp
Current assignee: Denso Corp
Priority date: 2005-12-02
Filing date: 2006-12-04
Publication date: 2010-05-26
Anticipated expiration: 2026-12-04
Also published as: JP4923545B2; JP2007159216A; CN1988326A

Abstract

An electric rotary machine, an armature for use in the electric machine, a method of forming an electric rotary machine and a forming machine for an armature of an electric rotary machine are disclosed wherein insulator-coated coils are wound in slots of an armature core from which lower and upper layer coil extensions extend and are connected to a commutator. The upper layer coil extension has a contour deformation part at an intersecting region where the lower and upper layer coil extensions intersect with each other to have an insulating distance between the lower and upper layer coil extensions. The forming machine includes a work holder holding the armature, and a forming jig forming a curvature portion on the upper layer coil extension.

Description

The method of electric rotary machine, armature, manufacturing electric rotary machine and the machine that forms armature

Technical field

The present invention relates to have the electric rotary machine of the armature coil of making by flat wire rod, and particularly relate to electric rotary machine, be used for the armature of electric rotary machine, the method for making electric rotary machine and the forming machine that is used for the armature of electric rotary machine.

Background technology

In recent years, be used to be installed in electric rotary machine (particularly starter) on the vehicle and need attempt to make the structure miniaturization, be intended to reduce installing space, and improve fuel consumption by in light weight.For this reason, attempt to provide the model of the armature coil that adopts flat wire rod,, increase output torque, thus by the miniaturization that realizes armature in light weight so that the lamination rate of improving is provided.

But, be well known that flat wire rod is in upper coil and the cross one another intersection region of lower coil and has the creeping distance narrower than circular wire rod between upper coil and the lower coil, guarantee safe insulation apart from the time meet difficulty.In addition, flat wire rod is difficult to form coil groups (particularly on the long side direction of wire rod), goes wrong when the insulation distance of guaranteeing between the upper and lower coil of locating between the coil of cross one another upper and lower.

In order to address this is that, United States Patent (USP) NO.5619088 proposes to be used for the armature of electric rotary machine.As shown in Figure 7, armature has cross one another lower coil extension 100 and upper coil extension 200.Lower coil extension 100 and upper coil extension 200 form otch (step) part 110,210 respectively in bottom and place, upper coil extension 100,200 cross one another intersection region, guarantee the clearance for insulation between these coil extensions 100,200 thus.

Adopt this prior art constructions, it is die-cut to carry out pressure in the zone at place, intersection region for lower coil extension 100 and upper coil extension 200, makes notch portion 110,210 form.Adopt the notch portion 110,210 by the die-cut formation of pressure, burr is formed on the edge of notch portion 110,210.What worried is that these burrs cause coil covering to damage, and occurs short circuit thus.When attempting to remove burr, increased artificial amount, the result increases manufacturing cost.

In addition, lower coil extension 100 and upper coil extension 200 are carried out pressure is die-cut to cause insulation film to peel off from lower coil extension 100 and upper coil extension 200 respectively to form otch (step) part 110,210.This causes short circuit phenomenon to increase.

Will carry out the die-cut coil quantity of pressure from about 100 to 200.Therefore, need carry out many pressure die-cut operation amounts, the load of pressure mould carrying increases, and what worried is to shorten die life.

In addition, the burr that causes in the die-cut process of pressure is retained on the coil, causes adverse influence in later step.

In addition, the burr that occurs in the die-cut process of pressure flies away from equipment, causes the artificial increase of cleaning equipment.

The short circuit phenomenon that occurs in order to solve needs a large amount of layer insulation sheet materials is arranged between upper coil extension 100 and the upper coil extension 200.This causes the increase of number of components, and the structure of manufacturing equipment becomes complicated.

Summary of the invention

The present invention is directed to the above-described problem of solution finishes, and its purpose is a kind of electric rotary machine, a kind of armature of electric rotary machine, a kind of method and a kind of forming machine that is used for the armature of electric rotary machine of making electric rotary machine of being used for, wherein insulation distance can be arranged between the two at the place, intersection region of upper and lower layer line circle extension, and on the layer line circle extension of upper and lower, do not form step part at place, mutual intersection region, do not cause insulation film to peel off from upper and lower layer line circle extension.

For this reason, one aspect of the present invention provides a kind of electric rotary machine, and this electric rotary machine comprises the yoke that is loaded with a plurality of permanent magnets on it and be fixedly supported upon the armature core that also is arranged in rotationally on the armature shaft in the yoke that it has the neighboring that forms a plurality of strias.The armature coil of a plurality of coating insulators is wound on multilayer form in the stria of armature core, each coil comprise be formed on top and lower layer arranged in form in each stria the bottom and the flat wire rod in the upper layer coil.Commutator is fixedly supported upon on the armature shaft at one end place, and has in its a plurality of conductor section on equidistant neighboring that is arranged in armature shaft on circumferentially, and conductor section comprises the riser (riser) that is electrically connected with bottom and upper layer coil respectively.Bottom and upper layer coil comprise lower layer coil extension and the upper layer coil extension of extracting out from each stria of armature core, and at least one bottom and upper layer coil extension comprise in the area that is formed on lower layer coil extension and place, the cross one another intersection region of upper layer coil extension the profile crushed element in case at lower layer coil extension and place, upper layer coil extension intersection region and between form insulation distance.

Adopt above-described structure, because at least one bottom and upper layer coil extension comprise the profile crushed element in the area that is formed on lower layer coil extension and place, the cross one another intersection region of upper layer coil extension, insulation distance can be arranged between the two at lower layer coil extension and place, upper layer coil extension intersection region.For the armature coil of electric rotary machine, this makes it can adopt thick flat wire rod, promptly has the flat wire rod of the vertical length of increase, makes the structure of electric rotary machine have lightweight miniaturization structure.

In addition, adopt aforesaid structure, upper and lower layer line circle extension does not need to comprise the interior notch portion (step part) in area that is formed on the cross one another intersection region of layer line circle extension, upper and lower by the required pressure die-cut operation of described prior art.Therefore, upper and lower layer line circle extension does not have because the burr that causes of pressure die-cut operation, and does not need to carry out the operation of deburring, makes it can realize manually reducing.

Adopt the electric rotary machine of current embodiment, the riser of each stria can have the riser stria of the far-end that holds the bottom that forms the upper and lower layer and upper layer coil extension therein, the far-end of its middle and lower part and upper layer coil extension has the apparent surface who covers insulation film respectively, this film melts by fusion, makes the mutual electric and mechanical bond of far-end of bottom and upper layer coil extension.

Adopt aforesaid structure, upper and lower layer line circle extension has the interior far-end of stria that the conductor section of inserting commutator forms the riser of part, does not need to peel off insulating barrier in advance from the far-end of relevant coil extension.Therefore, coil extension in upper and lower can have the minimum clearance that broadens at place, the cross one another intersection region of upper and lower layer line circle extension.Therefore, need not make coil groups so that between the layer line circle extension of upper and lower, obtain to have enough clearance for insulations with flat wire rod.

In addition, exist the upper and lower layer line circle extension that covers insulation film to make clearance for insulation in a small amount be arranged between the layer line circle extension of upper and lower at the place, intersection region that upper and lower coil extension becomes close mutually.Therefore, can in the insulation between the layer line circle extension of upper and lower, obtain stabilised quality, and not cause the layer insulation sheet material to be placed between two relevant coil extensions.

Adopt the electric rotary machine of current embodiment, the profile crushed element of at least one bottom and lower layer coil extension can comprise the reverse part in the area that is formed on lower layer coil extension and the cross one another intersection region of upper layer coil extension.

Adopt aforesaid structure, because the profile crushed element at least one bottom and upper layer coil extension place forms by the reverse part, the profile crushed element can be taked the structure simplified, and does not cause any increase of electric rotary machine cost.Equally, make the neighboring of armature form by the existence of the profile crushed element that forms of reverse part, and do not cause the armature radial dimension to increase with compactly designed.Therefore, electric rotary machine can form the miniaturization size, and does not cause the effective cross-sectional area of the flat wire rod that forms armature coil to reduce.

Adopt the electric rotary machine of current embodiment, the profile crushed element of at least one bottom and upper layer coil extension can comprise the sweep in the area that is formed on lower layer coil extension and place, the cross one another intersection region of upper layer coil extension.

Adopt aforesaid structure, because the profile crushed element of at least one bottom and upper layer coil extension is formed by sweep, the profile crushed element is taked the form of simplified structure, and does not cause any increase of the cost of electric rotary machine.Equally, the existence of the profile crushed element that is formed by sweep makes the neighboring of armature form with compactly designed, and does not cause the armature radial dimension to increase.Therefore, electric rotary machine can form the miniaturization size, and does not cause the effective cross-sectional area of the flat wire rod that forms armature coil to reduce.

Adopt the electric rotary machine of current embodiment, lower layer coil extension can be in the area of section that has the area of section that is substantially equal to lower layer coil extension before and after it in the area at lower layer coil extension and the cross one another intersection region of upper layer coil extension.

Adopt aforesaid structure, lower layer coil extension and upper layer coil extension do not need to form stepped portion, significantly do not reduce the area of section of each coil extension.That is, lower layer coil extension is in the area of section that has the area of section that is substantially equal to lower layer coil extension before and after it in the area at lower layer coil extension and the cross one another intersection region of upper layer coil extension.Equally, upper layer coil extension has the area of section of the area of section that is substantially equal to upper layer coil extension in the area before and after the intersection region that lower layer coil extension and upper layer coil extension intersect is in it.Therefore, two coil extensions significantly do not reduce at the area of section at its place, intersection region, it can be formed can suppress that calorific capacity increases and power output is degenerated has the structure of outstanding stable on heating electric rotary machine simultaneously.

Adopt the electric rotary machine of current embodiment, the flat wire rod that is used for each armature coil can form by stretching step.

In that circular wire rod is become in the metal rolling process of flat wire rod, work hardening appears in flat wire rod, cause to be difficult on flat wire rod, form the profile crushed element.Compare with this metal rolling, form flat wire rod by stretching step and cause less work hardening, make it form the profile crushed element of coil easily.

Adopt the electric rotary machine of current embodiment, the reverse part of at least one bottom and upper layer coil extension can have the area of section that its main shaft tilts with given angle with respect to the main shaft of the area of section of another extension in bottom and the upper layer coil extension.

Adopt aforesaid structure, because the reverse part of at least one bottom and upper layer coil extension tilts with respect to the main shaft of the area of section of another extension of bottom and upper layer coil extension, the profile crushed element can form simplified structure, and does not cause electric rotary machine to form labyrinth.

Adopt the electric rotary machine of current embodiment, the sweep of at least one bottom and upper layer coil extension can comprise with curved shape and is formed on plastic deformation part at least one bottom and the upper layer coil extension.

Adopt aforesaid structure,, do not have insulation film to peel off from sweep owing to comprise the existence of the sweep of plastic deformation part.Therefore, upper and lower layer line circle extension does not need to guarantee the insulation distance of the inappropriate increase between the relevant coil extension.In addition, sweep can form the structure of minimal deformation, causes the stress that forms at least one relevant coil extension to reduce.

According to another aspect of the present invention, a kind of armature that is used for electric rotary machine is provided, this armature comprises armature shaft, is fixedly supported upon on the armature shaft and is applicable to the armature core that rotates that in electric rotary machine it has the neighboring that forms a plurality of strias.The armature coil of a plurality of coating insulators is wound on multilayer form in the stria of armature core, each coil comprise be formed on top and lower layer arranged in form in each stria the bottom and the flat wire rod in the upper layer coil.Commutator is fixedly supported upon on the armature shaft at one end place, and has in its a plurality of conductor section on equidistant neighboring that is arranged in armature shaft on circumferentially, and conductor section comprises the riser that is electrically connected with bottom and upper layer coil respectively.Bottom and upper layer coil comprise lower layer coil extension and the upper layer coil extension of extracting out from each stria of armature core, and at least one bottom and upper layer coil extension comprise in the area that is formed on lower layer coil extension and place, the cross one another intersection region of upper layer coil extension the profile crushed element in case at lower layer coil extension and place, upper layer coil extension intersection region and between form insulation distance.

Adopt aforesaid structure, because at least one bottom and upper layer coil extension comprise the profile crushed element in the area that is formed on lower layer coil extension and place, the cross one another intersection region of upper layer coil extension, can be at lower layer coil extension and place, upper layer coil extension intersection region and between guarantee enough insulation distances.For the armature coil of electric rotary machine, this makes it can adopt thick flat wire rod, promptly has the flat wire rod of the vertical length of increase, makes the structure of electric rotary machine have lightweight miniaturization structure.

Employing is according to the armature that is used for electric rotary machine of the present invention, the riser of each stria can have the riser stria of the far-end that holds the bottom that forms the upper and lower layer and upper layer coil extension therein, the far-end of its middle and lower part and upper layer coil extension has the apparent surface who covers insulation film respectively, this film melts by fusion, makes the mutual electric and mechanical bond of far-end of bottom and upper layer coil extension.

Employing is according to the armature that is used for electric rotary machine of the present invention, and the profile crushed element of at least one bottom and lower layer coil extension can comprise the reverse part in the area that is formed on lower layer coil extension and the cross one another intersection region of upper layer coil extension.

Employing is according to the armature that is used for electric rotary machine of the present invention, and the profile crushed element of at least one bottom and upper layer coil extension can comprise the sweep in the area that is formed on lower layer coil extension and place, the cross one another intersection region of upper layer coil extension.

Employing is according to the armature that is used for electric rotary machine of the present invention, and lower layer coil extension can be in the area of section that has the area of section that is substantially equal to lower layer coil extension before and after it in the area at lower layer coil extension and the cross one another intersection region of upper layer coil extension.

Employing is according to the armature that is used for electric rotary machine of the present invention, and the flat wire rod that is used for each armature coil can form by stretching step.

Employing is according to the armature that is used for electric rotary machine of the present invention, and the reverse part of at least one bottom and upper layer coil extension can have the area of section that its main shaft tilts with given angle with respect to the main shaft of the area of section of another extension in bottom and the upper layer coil extension.

Employing is according to the armature that is used for electric rotary machine of the present invention, and the sweep of at least one bottom and upper layer coil extension can comprise with curved shape and is formed on plastic deformation part at least one bottom and the upper layer coil extension.

According to another aspect of the present invention, a kind of method of making electric rotary machine is provided, this method comprises that preparation is fixedly supported upon on the armature shaft and has the armature core of the neighboring that is formed with a plurality of strias and to be carried on commutator on the armature shaft with the aspectant relation of armature core, commutator comprises and circumferentially is placed on equally spaced locational a plurality of conductor section, conductor section has riser respectively, and in the stria of armature core, apply the coil of insulators, make coil that the upper and lower applies insulator be arranged in each stria in the mode of top and lower layer with reel a plurality of upper and lowers of multilayer mode.The coil of upper and lower coating insulator leaves the stria of armature core respectively as upper and lower layer line circle extension, and the profile crushed element is formed at least one bottom and the upper layer coil extension in the area at lower layer coil extension and place, the cross one another intersection region of upper layer coil extension, so that form insulation distance between lower layer coil extension and upper layer coil extension.The far-end of bottom and upper layer coil extension is electrically connected on each riser of conductor section of commutator.

The method of electric rotary machine is made in employing according to the present invention, because armature formation method is included in the area at place, the cross one another intersection region of lower layer coil extension and upper layer coil extension and forms the profile crushed element, can be at lower layer coil extension and place, upper layer coil extension intersection region and between convenient and guarantee enough insulation distances reliably.Thus, thick flat wire rod (promptly having the flat wire rod that increases vertical length) can be used for the coil of the armature of electric rotary machine.This formation can be made the ability of the structure of the electric rotary machine with lightweight miniaturization structure.

In addition, adopt described armature formation method, upper and lower layer line circle extension does not need to comprise the interior notch portion (step part) in area that is formed on the cross one another intersection region of layer line circle extension, upper and lower by the required pressure die-cut operation of described prior art.Therefore, upper and lower layer line circle extension does not have because the burr that causes of pressure die-cut operation, and does not need to carry out the operation of deburring, makes it can realize manually reducing.

Employing is according to the method for manufacturing electric rotary machine of the present invention, the riser of each stria can have the riser stria of the far-end that holds the bottom that forms the upper and lower layer and upper layer coil extension therein, the far-end of its middle and lower part and upper layer coil extension has the apparent surface who covers insulation film respectively, this film melts by fusion, makes the mutual electric and mechanical bond of far-end of bottom and upper layer coil extension.

Employing is according to the method for manufacturing electric rotary machine of the present invention, and upper and lower layer line circle extension has the interior far-end of stria that the conductor section of inserting commutator forms the riser of part, does not need to peel off insulating barrier in advance from the far-end of relevant coil extension.Therefore, coil extension in upper and lower can have the minimum clearance that broadens at place, the cross one another intersection region of upper and lower layer line circle extension.Therefore, need not make coil groups so that between the layer line circle extension of upper and lower, obtain to have enough clearance for insulations with flat wire rod.

Employing is according to the method for manufacturing electric rotary machine of the present invention, and the profile crushed element of at least one bottom and lower layer coil extension can comprise the reverse part in the area that is formed on lower layer coil extension and the cross one another intersection region of upper layer coil extension.

Adopt described armature formation method, because the profile crushed element at least one bottom and upper layer coil extension place forms by the reverse part, the profile crushed element can be taked the structure simplified, and does not cause any increase of electric rotary machine cost.Equally, make the neighboring of armature form by the existence of the profile crushed element that forms of reverse part, and do not cause the armature radial dimension to increase with compactly designed.Therefore, electric rotary machine can form the miniaturization size, and does not cause the effective cross-sectional area of the flat wire rod that forms armature coil to reduce.

Employing is according to the method for manufacturing electric rotary machine of the present invention, and the profile crushed element of at least one bottom and upper layer coil extension can comprise the sweep in the area that is formed on lower layer coil extension and place, the cross one another intersection region of upper layer coil extension.

Adopt described armature formation method, because the profile crushed element of at least one bottom and upper layer coil extension is formed by sweep, the profile crushed element is taked the form of simplified structure, and does not cause any increase of the cost of electric rotary machine.Equally, the existence of the profile crushed element that is formed by sweep makes the neighboring of armature form with compactly designed, and does not cause the armature radial dimension to increase.Therefore, electric rotary machine can form the miniaturization size, and does not cause the effective cross-sectional area of the flat wire rod that forms armature coil to reduce.

Employing is according to the method for manufacturing electric rotary machine of the present invention, and lower layer coil extension can be in the area of section that has the area of section that is substantially equal to lower layer coil extension before and after it in the area at lower layer coil extension and the cross one another intersection region of upper layer coil extension.

Adopt described armature formation method, lower layer coil extension and upper layer coil extension do not need to form stepped portion, significantly do not reduce the area of section of each coil extension.That is, lower layer coil extension is in the area of section that has the area of section that is substantially equal to lower layer coil extension before and after it in the area at lower layer coil extension and the cross one another intersection region of upper layer coil extension.Equally, upper layer coil extension has the area of section of the area of section that is substantially equal to upper layer coil extension in the area before and after the intersection region that lower layer coil extension and upper layer coil extension intersect is in it.Therefore, two coil extensions significantly do not reduce at the area of section at its place, intersection region, it can be formed can suppress that calorific capacity increases and power output is degenerated has the structure of outstanding stable on heating electric rotary machine simultaneously.

Employing is according to the method for manufacturing electric rotary machine of the present invention, and the flat wire rod that is used for each armature coil can form by stretching step.

Employing is according to the method for manufacturing electric rotary machine of the present invention, and the reverse part of at least one bottom and upper layer coil extension can have the area of section that its main shaft tilts with given angle with respect to the main shaft of the area of section of another extension in bottom and the upper layer coil extension.

Adopt described armature formation method, because the reverse part of at least one bottom and upper layer coil extension tilts with respect to the main shaft of the area of section of another extension of bottom and upper layer coil extension, the profile crushed element can form simplified structure, and does not cause electric rotary machine to form labyrinth.This also makes armature component quantity reduce, and reduces manufacturing cost.

Employing is according to the method for manufacturing electric rotary machine of the present invention, and the sweep of at least one bottom and upper layer coil extension can comprise with curved shape and is formed on plastic deformation part at least one bottom and the upper layer coil extension.

Adopt described armature formation method,, do not have insulation film to peel off from sweep because sweep comprises the plastic deformation part.Therefore, upper and lower layer line circle extension does not need to guarantee the insulation distance of the inappropriate increase between the relevant coil extension.In addition, sweep can form the structure of minimal deformation, causes the stress that forms at least one relevant coil extension to reduce.

According to another aspect of the present invention, provide a kind of forming machine that is used for the armature of electric rotary machine.This armature has armature shaft, is fixedly supported upon on the armature shaft and is applicable to the armature core that rotates in electric rotary machine, and it has the neighboring that forms a plurality of strias.The armature coil of a plurality of coating insulators is wound on multilayer form in the stria of armature core, each coil comprise be formed on top and lower layer arranged in form in each stria the bottom and the flat wire rod in the upper layer coil.Commutator is fixedly supported upon on the armature shaft at one end place, and has in its a plurality of conductor section on equidistant neighboring that is arranged in armature shaft on circumferentially, and conductor section comprises the riser that is electrically connected with bottom and upper layer coil respectively.Bottom and upper layer coil comprise lower layer coil extension and the upper layer coil extension of extracting out from each stria of armature core.At least one bottom and upper layer coil extension comprise in the area that is formed on place, the cross one another intersection region of lower layer coil extension and upper layer coil extension the profile crushed element in case at lower layer coil extension and place, upper layer coil extension intersection region and between form insulation distance.Thereby this forming machine comprises the processing maintaining body that operationally armature core remained on the given position, can operate so that be placed on the neighboring of armature core the coil limit collar that upper layer coil extension is limited in just from the stage that the stria of armature core is extracted out.Forming jig can be operated so that insert gap between the upper and lower layer line circle extension of extracting out from the stria of armature core, and comprises shaped portion so that form the profile crushed element at least one bottom and upper layer coil extension.Pressure punch can be operated so that shaped portion is pressed in the neighboring of at least one bottom and upper layer coil extension.

Adopt aforesaid structure, the profile crushed element is the shape of form formation forming jig effectively.

In addition, the coil limit collar can just limit the periphery wall of upper layer coil extension in upper layer coil extension area after the relevant stria of armature core is extracted out on it is axial.This prevents upper layer coil extension because its reaction force and raising on radially outer direction of causing in pressure punch presses the operating process of shaped portion of forming jig.This formation prevents the ability of upper layer coil extension and armature core short circuit.Equally, the profile crushed element can highly reliable mode form shape accurately.

Employing is according to the forming machine that is used for the armature of electric rotary machine of the present invention, forming jig comprises the insertion tongue that is applicable to the gap between the layer line circle extension of insertion upper and lower and is formed with shaped portion, shaped portion has the both sides that are formed with wall surface, between wall surface, form coil and insert recess, so that hold upper layer coil extension and it is remained on the fixed position.

Adopt aforesaid structure, the insertion tongue can insert the gap between the layer line circle extension of upper and lower, and has shaped portion, shaped portion has the both sides that are formed with wall surface, between wall surface, form coil and insert recess, upper layer coil extension can be contained in coil and insert in the recess, so that in highly reliable mode upper layer coil extension is remained on the fixed position.That is, when the profile crushed element being formed on the upper layer coil extension, upper layer coil extension can remain under the stable status, makes the profile crushed element be positioned on the upper layer coil extension in highly reliable mode.

Employing is inserted tongue and is had the inclined lead wall that reduces radial thickness from the tip portion of shaped portion towards its distal portions according to the forming machine that is used for the armature of electric rotary machine of the present invention.

Adopt aforesaid structure, form the inclined lead wall the insertion tongue be arranged so that insert tongue can by and the less contact resistance of upper layer coil extension insert gap between bottom and the upper layer coil extension.Therefore, insert tongue and can insert between bottom and the upper layer coil extension, the efficient that making is shaped processes increases.

Employing is according to the forming machine that is used for the armature of electric rotary machine of the present invention, and pressure punch has the far-end that forms R shape with respect to the longitudinal axis of upper layer coil extension, and has given width with respect to the Width of upper layer coil extension.

Adopt aforesaid structure, when pressure punch pressed upper layer coil extension, pressure punch was by minimum contact surface area contact upper layer coil extension.This has suppressed the degeneration of the insulation film of covering upper layer coil extension.Equally, the setting with pressure punch of the far-end that forms R shape can suppress the appearance that the far-end stress of pressure punch is concentrated.This can prevent the crackle of pressure punch or break, and the operation lifetime of prolongation is provided.

Employing is according to the forming machine that is used for the armature of electric rotary machine of the present invention, and the width of pressure punch can be defined as equaling or slightly greater than the width of upper layer coil extension.

Adopt aforesaid structure, pressure punch can press the overall width of upper layer coil extension, can prevent the local deformation of upper layer coil extension thus, avoids the degeneration of the insulation film of upper layer coil extension simultaneously.

Employing is according to the forming machine of the armature of electric rotary machine of the present invention, and forming jig can have the neighboring that is formed with the drift guide notch, so that pressure punch is directed on the given position on the upper layer coil extension.

Adopt aforesaid structure, the location of pressure punch can be finished by convenient and reliable mode, makes upper layer coil extension form the profile crushed element with stationary mode.

Employing is according to the forming machine that is used for the armature of electric rotary machine of the present invention, and Internal jigging can be installed in the forming jig, so that the inner rim of restriction lower layer coil extension.

Adopt aforesaid structure, forming jig inserts between the layer line circle extension of upper and lower, can prevent that lower layer coil extension from radially curving inwardly.This forms operation reliably, so that form the profile crushed element of upper layer coil extension with efficient way.

Description of drawings

Fig. 1 is combined with according to half sectional view of the starter of the electric rotary machine of the first embodiment of the present invention;

Fig. 2 is half the sectional view of armature of the electric rotary machine of first embodiment shown in Figure 1;

Fig. 3 is the amplification sectional view of armature shown in Figure 2;

Fig. 4 is the sectional view along the upper and lower layer line circle extension shaped portion of the coil shown in Figure 3 of the line A-A intercepting of Fig. 3;

Fig. 5 is the schematic diagram of expression armature coil connection line figure;

Fig. 6 A is the amplification sectional view along the armature shown in Figure 3 of the line B-B intercepting of Fig. 3;

Fig. 6 B is the sectional view of far-end of upper and lower layer line circle extension shaped portion of the variant of the first embodiment armature;

Fig. 7 is the perspective view of upper and lower layer line circle extension of the armature of prior art electric rotary machine;

Fig. 8 A is the amplification sectional view of armature of the formation electric rotary machine of prior art;

Fig. 8 B is the sectional view of the upper and lower layer line circle extension far-end of the armature shown in Fig. 8 A;

Fig. 9 is the enlarged perspective according to the armature of the formation electric rotary machine of second embodiment of the invention, and wherein upper and lower layer line circle extension is extracted out from the relevant stria of armature core;

Figure 10 is the schematic diagram of general structure that expression is used to form the armature forming machine of armature shown in Figure 9;

Figure 11 is the amplification sectional view of operative relationship between the coil limit collar of armature forming machine shown in Figure 10 and the forming jig;

Figure 12 is the plane graph of coil limit collar shown in Figure 11;

Figure 13 A is the front view of the forming jig of armature forming machine shown in Figure 10;

Figure 13 B is the sectional view of the forming jig shown in Figure 13 A;

Figure 14 is illustrated in the amplification sectional view that forms the step of profile crushed element before the upper periphery of pressure punch contact upper layer coil extension on upper layer coil extension;

Figure 15 is illustrated in pressure punch to form the amplification sectional view that forms the step of profile crushed element after the profile crushed element on upper layer coil extension on upper layer coil extension.

Embodiment

Now, describe electric rotary machine according to a plurality of embodiment of the present invention in detail with and related methods below with reference to accompanying drawing.But, think that the present invention is not limited to the embodiment that describes below, and the technological concept of the present invention application that can combine with other technique known, or with have the application that combines with other technology of this known technology identical functions.

In being described below, similarly reference number refers to similar or corresponding parts in a plurality of accompanying drawings.Equally in the following description, omit the identical parts of the parts with first embodiment of second embodiment, but the identical parts of the parts with first embodiment that will appreciate that second embodiment refer to first embodiment those use the parts of similar reference number.

[first embodiment]

Now, describe the starter 1 of conduct in detail below with reference to accompanying drawing according to the electric rotary machine of the first embodiment of the present invention.Fig. 1 is the view in cross section of the first half of expression starter 1, and Fig. 2 is the view of the first half of expression armature 14.

As shown in Figure 1, the starter 1 of first embodiment comprise can operate in case produce driving torque motor 2, reduce the gear reduction unit 3 of the velocity of rotation of motor 2, place with concentric relation with the motor drive shaft 2a of motor 2 so as via gear reduction unit 3 receive driving torques output shaft 4, be formed on the pinion 6 on the neighboring with the output shaft 4 of its formation integral body and be parallel to motor 2 and place and can operate to drive the electromagnetic switch 8 of gear lever 7, by gear lever 7, clutch 5 and pinion 6 and motor 2 travel forward on the contrary (as shown in Figure 1 left).Electromagnetic switch 8 also can be operated so that closure or openness are combined in the main contacts (describing subsequently) in the energized circuit (after this becoming motor loop).

Motor 2 comprises the DC motor, this motor have have be installed with a plurality of permanent magnets 10 in case form the inner rim of flux field cylindrical yoke 9, have fixing carrying on it armature shaft 11 and be wound with armature coil 13 and be rotatably supported in the armature 14 of the armature core 12 in the area of inner rim inside of permanent magnet 10, and a plurality of carbon brush 16 that are used for electric energy is fed to from the battery (not shown) armature 14.

Gear reduction unit 3 be included in the concentric axis of armature shaft 11 on carry out gear reduction so that the orbital motion of planetary gear 17 is delivered to the epicyclic reduction gear of planetary type unit of output shaft 4.

Output shaft 4 is placed to concentric relation with armature shaft 11, and have via bearing 18 by housing 19 rotatable support front end and be connected to rear end on the gear reduction unit 3.

Clutch 5 is to be connected on the neighboring of output shaft 4 and can to operate so that the driving torque of output shaft 4 is delivered to spline on the pinion 6 when engine start.In addition, clutch 5 comprises the one-way clutch with following structure construction, promptly when pinion 6 passes through engine rotation, that is to say when the velocity of rotation of pinion 6 surpasses the velocity of rotation of output shaft 4, the power interruption of transmitting between output shaft 4 and pinion 6 is delivered on the output shaft 4 so that prevent the rotation of pinion 6.

Pinion 6 is installed on the clutch 5 in its side relative with motor 2, and on output shaft 4 and clutch 5 together with integral way axial motion forward, so that engage with the set of gears (not shown) engagement of engine, the rotatory force of transmitting via clutch 5 is delivered on the gear ring thus.

Electromagnetic switch 8 comprises energising so that response is from the solenoid (not shown) of the electric energy of on-vehicle battery supply and the plunger (not shown) of axial motion in the inner rim of solenoid 13 when activator switch is closed.So that when forming electromagnet, electromagnet attracts plunger so that near main contacts when solenoid energising.In addition, so that when stopping the attraction of electromagnet, because the reaction force of return spring (not shown), plunger turns back to its home position when solenoid outage, Open from This Side main contacts.

Main contacts comprises via two terminal bolts 20,21 and is connected to one group of fixed contact (not shown) on the motor loop and is applicable to plunger with integral way motion so that be connected to or break away from the moving contact (not shown) of fixed contact.

Two terminal bolts 20,21 comprise via the battery cable and are connected to the B terminal bolt 20 on the on-vehicle battery and are connected to M terminal bolt 21 on the lead of extracting out from motor 2 22 that wherein two terminals are fixed on the contact lid 23 of electromagnetic switch 8.

Gear lever 7 have swinging mounting on housing 10 bar fulcrum 7a and from the upwardly extending rod end part 7b of bar fulcrum 7a, rod end partly is connected on the selector bar 24 on the plunger that is installed in electromagnetic switch 8.Bar 7 has another rod end part 7c that extends from bar fulcrum 7a downwards, and this boom end divides and keeps engaging with clutch 5, so that the Motion Transmission of plunger is arrived clutch 5.That is, attract plunger so that it when moving right as shown in Figure 1, is connected to rod end part 7b on the selector bar 24 by the plunger pulling and move right at electromagnet.This makes the rod end part 7c engages with clutch 5 swing around center of bar fulcrum 7a, causes clutch 5 release forward on the direction relative with motor 2, promptly as described in Figure 1 to the right.

Then, armature coil 13 according to formation starter 1 part of the present invention is described below.

Armature coil 13 is included in the flat wire rod of a plurality of coating insulators of reeling in the multilayer mode in stria 25 (see figure 5)s on the neighboring that is formed on armature core 12.Particularly, each flat wire rod forms and inserts upper and lower coil 13B, the 13A of each stria 25 inside with top and lower layer mode.Bottom and upper layer coil extension 13Ae, 13Be have bottom and upper layer coil extension 13Ae, 13Be respectively, and its far-end 13a, 13b are connected on the commutator 15.Equally, flat wire rod forms by the drawing process with less work hardening, and inserts in the stria 25, and wherein the main shaft of flat wire rod is upwards aimed in the footpath of armature core 12.

As shown in Figure 2, armature shaft 11 has the rear end 11a of the cylindrical insulating component 26 of fixed bearing.Commutator 15 comprises with cylindrical structure at a plurality of conductor section 15as of circumferential equidistant position fixed and arranged on the neighboring of insulating component 26.

More especially, the cylindrical insulating component 26 rear end 11a that is included in armature shaft 11 goes up the cylindrical part 26a of carrying, the rear annular flange 26c that extends radially outwardly on the rear end that is formed on the forward annular flange 26b that extends radially outwardly on the front end of cylindrical part 26a and is formed on cylindrical part 26a.In addition, it is the rear surface of the circular ridge part 26d of triangular construction that forward annular flange 26b has its cross section of formation, and circular ridge part 26d keeps and the annular notch 15d engage that is formed on the front end place of conductor section 15a.The cylindrical part 26a of insulating component 26 has the periphery wall 26e that is installed with conductor section 15a.

Illustrate as Fig. 3 is clear, conductor section 15a forms the cross section of stock shape, and have and be formed with at the front end of the upwardly extending riser 15b in side radially outward, riser 15b has radially the stria 15c that extends so that insert far-end 13a, the 13b (seeing Fig. 6 A and 6B) of bottom and upper layer coil extension 13Ae, 13Be.

Equally, in the following description, the flat wire rod that inserts the lower layer of stria 25 refers to lower layer coil 13A.Equally, another flat wire rod of the upper layer of insertion stria 25 refers to upper layer coil 13B.

The identical stria 25 interior lower layer coil 13A that insert armature core 12 extract out from relevant stria 25 with upper layer coil extension 13Be as lower layer coil extension 13Ae diametrically with upper layer coil 13B, and subsequently with lower layer coil 13A and upper layer coil 13B be connected on the opposite circumferential direction of the direction of the section 15a of different conductor portion of commutator 15 crooked, as shown in Figure 5.Adopt this structure, lower layer coil 13A and the upper layer coil 13B that extracts out from the relevant stria 25 of armature core 12 has (part " X " expression among Fig. 5) cross one another circumferential skewing part in the intersection region diametrically.

At least one bottom of lower layer coil 13A and upper layer coil 13B and upper layer coil extension 13Ae, 13Be have the profile crushed element at upper layer coil extension 13Be and X place, the cross one another intersection region of lower layer coil extension 13Ae.That is, as shown in Figure 4, upper layer coil extension 13Be has the mid portion that is formed with profile crushed element 13B t.Profile crushed element 13Bt comprises in one direction at the place, centre position of upper layer coil extension 13Be and reversing so that cause the reverse part of the main shaft of upper layer coil extension 13Be with respect to the radial skew of armature core 12.Then, the reverse part is reversed and is got back to original orientation so that enter the stria 15c of the riser 15b of conductor section 15a, make upper layer coil extension 13Be main shaft with and the radially main shaft of lower layer coil extension 13Ae of coupling of armature core 12 aim at.

The operation of starter 1 is described now.

So that when forming electromagnet, electromagnet attracts plunger in the energising of the solenoid of starter closure and electromagnetic switch 8, and plunger moves right subsequently as shown in Figure 1.At this moment, the motion of plunger is delivered to clutch 5 via gear lever 7, and clutch and pinion 6 are leaving the upwards motion on output shaft 4 forwards of motor 2 together.Therefore, the end surfaces of pinion 6 abuts the end surfaces that engages gear ring, and stops in the fixed position.

Simultaneously, when the main contacts of plunger motion and motor loop was closed, motor 2 was supplied electric energy from on-vehicle battery, so that cause armature 14 power that rotates.The velocity of rotation of armature 14 is slowed down by reduction gear unit 3, and is delivered to output shaft 4 as driving torque, and therefrom driving torque further is delivered to pinion 5 via clutch 5.Therefore, pinion 6 turns to pinion 6 forcibly and can mesh and engage gear ring so that the driving torque of motor 2 is delivered to via pinion 6 on the position of gear ring, thus by the crank-motion ato unit.

When engine was opened by crank operation startup and activator switch, the solenoid outage was so that eliminate attraction.This makes the reaction force of return spring that plunger is pushed back the home position.At this moment, main contacts is opened, and interrupts being fed to from on-vehicle battery the electric energy of motor 2, and therefore the velocity of rotation of armature 14 reduces gradually, and stops.

In addition, when plunger pushes back, cause gear lever 7 with gear lever 7 the side during the engine start in the opposite direction on swing, the Motion Transmission of plunger is to clutch 5.Therefore, pinion 6 is thrown off from the gear ring of engine, and pinion 6 and clutch move rearwards to given position (that is, position shown in Figure 1) together on output shaft 4, and stops start-up operation.

(advantageous effects of first embodiment)

Adopt described starter 1, because at least one upper and lower layer line circle extension 13Be, 13Ae (being the upper lines ring layer 13Bbe of current embodiment) of extracting out from stria 25 comprise the reverse part 13Bt as the profile crushed element in bottom and upper layer coil extension 13Ae, the cross one another intersection region X of 13Be, insulation distance can be arranged on (see figure 4) between lower layer coil extension 13Ae and the upper layer coil extension 13Be fully at intersection region X place.This makes armature coil 13 to use to have increases the flat wire rod of thickness, and perhaps the flat wire rod of perpendicular elongate makes starter 1 realize lightweight miniaturization structure.

Employing is according to the starter 1 of first embodiment of the invention, do not need stepped portion to be formed on the layer line circle extension of upper and lower at lower layer coil extension 13Ae and place, the cross one another intersection region of upper layer coil extension 13Be by the pressure die-cut operation, the area of section of two upper layer coil 13Ae, 13Be at the place, intersection region significantly do not reduce.That is, lower layer coil extension 13Ae has the identical overall length of area of section in the area, front and back at its area of section and lower layer coil extension 13Ae and place, the cross one another intersection region of upper layer coil extension 13Be.Equally, upper layer coil extension 13Be has the identical overall length of area of section in the area, front and back at its area of section and lower layer coil extension 13Ae and place, the cross one another intersection region of upper layer coil extension 13Be.This makes two upper layer coil 13Ae, 13Be significantly not reduce at the area of section at place, intersection region, thereby can restrain calorific capacity.Therefore, the reduction of the output voltage of starter 1 can be reduced, thereby the structure of motor 2 of the heat resistance of increase can be realized having easily.

[modification of first embodiment]

With reference now to Fig. 6 A and 6B, the starter of the variations of first embodiment is described.Fig. 6 A is the amplification sectional view of armature 14A of the starter part of the local expression modification that forms first embodiment, wherein the stria 15c of the riser 15b of conductor section 15a holds end winding 13b, the 13b of lower layer coil extension 13A e and upper layer coil extension 13Be therein, and Fig. 6 B is the sectional view of expression end winding 13a, 13b.

Describe the starter of the variations of first embodiment below with reference to exemplary configurations, wherein insert the lower layer coil extension 13Ae of stria 15c of riser 15b and end winding 13a, the 13b of upper layer coil extension 13Be and mutually combine by fusing.

Before end winding 13a, the 13b of lower layer coil extension 13Ae that melts the stria 15c that inserts riser 15b and upper layer coil extension 13Be, remove the subregion of the insulation film that covers end winding 13a, 13b in advance.More especially, shown in Fig. 6 B, the bottom section Ifa of the insulation film of the end winding 13a of covering lower layer coil 13A is removed, and makes end winding 13a have flat lower surface.Equally, remove the upper area Ifb of the insulation film of the end winding 13b that covers upper layer coil extension 13Be, make end winding 13b have flat upper face.In other words, end winding 13a, the 13b of lower layer coil extension 13Ae and upper layer coil extension 13Be have opposed facing zone in the stria 15c of riser 15b, leave insulation film in this zone respectively.Therefore, end winding 13a, the 13b of lower layer coil extension 13Ae and upper layer coil extension 13Be inserts the stria 15c of the riser 15b of each conductor section 15a, wherein end winding 13a, 13b keep abutting joint mutually in the non-binding part of the location that covers insulation film, as shown in Figure 6A.Under this configuration status, the insulation film of end winding 13a, 13b melts by fusion, and mutual electric and mechanical bond.

In this way, the prior art structure shown in the employing, shown in Fig. 8 A and 8B, lower layer end winding 11 has top and bottom end wall 111a, the 111b that removes its insulation film in advance.Equally, upper layer end winding 211 has top and bottom end wall 211a, the 211b that removes its insulation film in advance.Subsequently, keep abutting mutually under the state of joint at the top end wall 111a of lower layer end winding 111 and the bottom end wall 211b of upper layer end winding 211, in the stria 310 of the riser 300 of two end winding 111,211 insertion conductor section.In this state, the bottom end wall 211b of the top end wall 111a of lower layer end winding 111 and upper layer end winding 211 is by the mutual electric and mechanical bond of fusion.For this prior art structure, the insulation film B1 that removes the bottom end wall 211b of the insulation film T 2 of top end wall 111a of lower layer end winding 111 and upper layer end winding 211 in advance causes the narrow minimum clearance between close mutually place, the intersection regions upper and lower layer line circle 211,111 of upper and lower layer line circle 211 and 111.

On the contrary, adopt the structure of armature of the variations of first embodiment, because insulation film is retained on the opposite end walls that is arranged in interior two end winding 13a, 13b of stria 25 of its main shaft and armature 14A with radially aiming at, can locate, between lower layer coil extension 13Ae and upper layer coil extension 13Be, guarantee the gap that broadens at lower layer coil extension 13Ae and the mutual close intersection region of upper layer coil extension 13Be.Thus, do not need flat conductor to form die-cut especially structure required in the prior art structure wittingly, so that obtain the insulation distance between lower layer coil extension and the upper layer coil extension, and insulation distance can obtain at lower layer coil extension and place, the cross one another intersection region of upper layer coil extension easily.

In addition, cover the relative wall of insulation film separately because lower layer coil extension 13Ae and upper layer coil extension 13Be have at lower layer coil extension 13Ae and the close mutually place, intersection region of upper layer coil extension 13Be, be enough in place, intersection region, space between lower layer coil extension 13Ae and upper layer coil extension 13Be, guarantee a small amount of insulation distance.Therefore, the armature of the starter of current embodiment can have stabilized quality in the gap between lower layer coil extension 13Ae and the upper layer coil extension 13Be.Therefore, do not need the layer insulation sheet material to be placed between lower layer coil extension 13Ae and the upper layer coil extension 13Be.

Though can use the modification of first embodiment separately, will appreciate that as required first and second embodiment can be used in combination.

[second embodiment]

Now, with reference to the armature of figure 9-15 description according to the starter of the second embodiment of the present invention.The armature of second embodiment is different from the profile crushed element that the first embodiment part is upper layer coil extension and comprises the sweep that is formed on upper layer coil extension and place, the cross one another intersection region of bottom upper layer coil extension.Equally, second embodiment is at the forming machine that is used for forming at the armature core from armature the upper layer coil extension formation sweep of part extraction.

Fig. 9 is the perspective view of the armature of the expression starter part that forms second embodiment.Figure 10-the 15th, expression is used for the view according to the forming machine of second embodiment of the present invention armature.

Adopt starter of the present invention, armature 14B is rotatably supported in the yoke 9 of starter 1, and structure as shown in Figure 1 is such.

Armature 14B comprises armature shaft 11, be fixedly mounted on armature core 12 on the armature shaft 11, be wound on the armature core 12 a plurality of armature coils 13 and at the commutator 15 that is fixedly mounted at one end place on the same structure as shown in Figure 1 on the armature shaft 11.

Armature core 12 also has the circumferential extension stria 25 (25 strias in structure shown in Figure 9) along the peripheral equidistant placement of armature core 12, as shown in Figure 9.Stria 25 is formed on the armature core 12 on its whole axial length.

Armature coil 13 comprises the copper wires that applies insulator, and is wound on the armature core 12, makes the copper wires that applies insulator insert in the stria 25 of armature core 12 with the form of top and lower layer.Armature coil 13 has upper layer coil 13A and upper layer coil 13B, and upper layer coil 13A and upper layer coil 13B have respectively from the bottom that an end of the stria 25 of armature core 12 is extracted out and upper layer coil extension 13Ae and 13Be and the distal coil end 13a, the 13b (seeing Fig. 1 and 2) that are connected on the commutator 15.

Adopt the armature 14B of second embodiment, as shown in Figure 9, in the stria 25 of armature core 12, and bottom and upper layer coil extension 13Ae, 13Be extract out from an end of armature core 12 with the arranged in form of bottom and upper layer for lower coil 13A and upper lines ring layer 13BB.Bottom and upper layer coil extension 13Ae, 13Be are crooked in the opposite direction on the periphery of armature core 12, so that be connected on the different conductor portion section, and with the same structure of describing with reference to first embodiment shown in Figure 5 in the X of intersection region, intersect mutually.

At the upper and lower of upper layer coil 13B and lower layer coil 13A layer line circle extension 13Be, X place, the cross one another intersection region of 13Ae, upper and lower layer line circle extension 13Be, the 13Ae of upper layer coil 13B and lower layer coil 13A are close mutually, insulation distance occurs between upper and lower layer line circle extension 13Be, the 13Ae.In order to address this is that, at least one upper layer coil extension 13Be, 13Ae (being the upper layer coil extension 13Be of current embodiment) have the profile crushed element, and this profile crushed element has the sweep 13Bc that locates to form at upper layer coil extension 13Be and the cross one another intersection region of lower layer coil extension 13Ae (as intersection region X shown in Figure 5).Setting comprises at the profile crushed element of the sweep 13Bc on the upper layer coil extension 13Be can guarantee enough insulation distances between upper layer coil extension 13Be and lower layer coil extension 13Ae, and need not form the pressure die-cut operation of stepped portion on upper layer coil extension 13Be and lower layer coil extension 13Ae.

Adopt second embodiment, use the forming machine 30 shown in Figure 10-15 to form this profile crushed element of upper layer coil extension 13Be.

More especially, the structure construction of forming machine 30 becomes to form sweep 13Bc on the upper layer coil extension 13Be of upper layer coil 13B, wherein commutator 15 is fixedly supported upon on the armature shaft 11, and promptly lower layer coil extension 13Ae and upper layer coil extension 13Be extract out from the stria 25 of armature core 12 in the axial direction.

With reference to Figure 10, forming machine 30 is expressed as comprising processing maintaining body 31, coil limit collar 32, forming jig 34, pressure punch 36 and Internal jigging 38.

Processing maintaining body 31 comprises from base 43 upright one group of workpiece receiver 40,42 and retention mechanism 44.

Described one group of workpiece receiver 40,42 be included in the position upper support armature shaft 11 relative with commutator front end 11b workpiece receiver 40 and near the position of commutator workpiece receiver 42 via the rear end 11b of forming jig 34 supporting armature shafts 11.

Retention mechanism 44 comprises fastening handle 45, the clamp structure 48 on the trip bolt 45a that extends forward via fastening column 46 from the upright fastening column 46 of base 43, from fastening handle 45 of part place and the rear end surface that is fixed on forming jig 34 in its back-end.Rotate fastening handle 45 and make the front end 45b of trip bolt 45a press the end surfaces of the rearmost end 11c of armature shaft 11, in the axial direction armature shaft 11 is remained on the fixed position thus.

As shown in figure 11, coil limit collar 32 just is placed on the neighboring of upper layer coil 13B the position after stria 25 extends diametrically at upper layer coil extension 13Be, and the neighboring of restriction upper coil 13B raises on radially outer direction in sweep 13Bc forming process so that prevent upper layer coil 13B.As shown in figure 12, coil limit collar 32 comprises upper and lower semicircle half part 32a, the 32b that connects into single-piece by a plurality of screw 32c, 32c.

As shown in FIG. 13A, forming jig 34 comprises cylindrical member 50, and the one end is in diapire 52 place's closures.Cylindrical member 50 has and extends axially circular inner hole 50a and be formed with a plurality of fore-ends that coil inserts recess 54 that extend axially, the quantity of recess equals to be formed on along the periphery of cylindrical member 50 quantity of the stria 25 of equidistant position, so that restriction is from the upper layer coil extension 13Be of the upper layer coil 13B of stria 25 extractions of armature core 12.

Shown in Figure 13 B, it is relevant with insertion tongue 56 on the front end that is formed on cylindrical member 50 that each coil inserts recess 54.Extend axially so that play insertion tongue 56 that coil inserts the diapire effect of recess 54 and have and be applicable to the shaped portion 56a that inserts the gap between lower layer coil extension 13A e and the upper layer coil extension 13Be in the axial direction and insert the wall part 54a that two peripheral side outward radials of recess 54 extend at coil.Shaped portion 56a is formed by the neighboring of the insertion tongue 56 that forms ridge-shape.Insert tongue 56 and form the oblique structure that reduces its radial thickness towards the forward distal ends of shaped portion 56a gradually.Insert tongue 56 and also have the rear portion curved incline part 56b continuous, so that on upper layer coil extension 13Be, form the sweep 13Bc of net shape with shaped portion 56a.In addition, forming jig 34 has the front area that forms a plurality of drift guide notch 50b that radially extend in the position near the shaped portion 56a that inserts tongue 56.Centre bore 52a and set bolt 58 that the terminal 11c that the diapire 52 of forming jig 34 has an armature shaft 11 extends through wherein extend through wherein a plurality of bolt heads hole 52b and a plurality of bolt-inserting hole 52c respectively.

The pressure punch 36 that is placed on the upper layer coil extension 13Be radially outer position that remains on the upper lines ring layer 13B in the coil patchhole recess 54 has the distal lower end 36a of the guide notch 50b that inserts the cylindrical member 50 that passes forming jig 34.The far-end 36a of pressure punch 36 has the bottom of stretching into coil insertion recess 54, and when pressurized, the far-end 36a of pressure punch 36 presses the upper layer coil extension 13Be of upper lines ring layer 13BB.

Adopt pressure punch 36, far-end 36a has the bottom that forms circular R shape of pressing upper layer coil extension 13Be, and upwards has given width in week.The far-end 36a that the width of the far-end 36a of pressure punch 36 is chosen to have pressure punch 36 can insert the size among the guide recess 50b of forming jig 34, and this size is greater than the circumferential width of upper layer coil extension 13Be.

Get back to Figure 10, internal holes 38a, 38b, 38c, end 11a and terminal 11c that Internal jigging 38 has the cylindrical outer structure respectively and is used to hold armature shaft 11.Internal jigging 38 is contained in the cylindrical hole 34a, and by the fixed bearing therein of the set bolt 58 on the diapire 52 that is bearing in forming jig 34, wherein between the outside cylindrical surface of the cylindrical wall 34a of forming jig 34 and Internal jigging 38, limit given annular guide space 62 via the annular bearing plate 60 on the cylindrical hole 34a that is installed in forming jig 34.Adopt this structure, Internal jigging 38 inserts in the zone of lower layer coil extension 13Ae inner radial, and plays the effect of the restraint device of the inner rim of restriction lower layer coil extension 13Ae when the gap of inserting between tongue 56 insertion bottoms and upper layer coil extension 13Ae, the 13Be.

Then, will method that use forming machine 30 to form shaped portion 13Bc on upper layer coil extension 13Be be described.

At first, forming jig 34 and Internal jigging 38 are inserted in lower layer coil extension 13Ae and the upper layer coil extension 13Be that upwards extract out from the relevant stria 25 of armature core 12 in the footpath of armature 14.That is, Internal jigging 38 inserts the inner radial zone of lower layer coil extension 13Ae.Equally, insert the gap that tongue 56 inserts between lower layer coil extension 13Ae and the upper layer coil extension 13Be.In this case, the coil that upper layer coil extension 13Be stretches into forming jig 34 inserts recess 54, and fixedly remains on the fixed position.

Subsequently, coil limit collar 32 location also is installed on the corner region of neighboring of armature core 12, thus in the neighboring of the position restriction upper layer coil extension 13Be that just extends from the relevant stria 25 of armature core 12.Then, the insertion tongue 56 of forming jig 34 inserts between upper and lower layer line circle extension 13Ae, the 13Be, makes upper layer coil extension 13Be guide simultaneously and fixedly remains on coil and insert in the recess 54.Subsequently, pressure punch 36 radially inwardly presses via drift guide notch 50b, causes far-end 36a to press upper layer coil extension 13Be.Thus, upper layer coil extension 13Be is formed with sweep 13Bc, as the profile crushed element of the shape of the shaped portion 56a that follows forming jig shown in Figure 15 34.

When finishing the pressure die-cut operation of the sweep that forms upper layer coil extension 13Be, armature core 12 and forming jig 34 turn over the rotational angle that equals a stria.In this case, reduction pressure punch 36 can be carried out step subsequently, so that form another sweep 13Bc on another upper layer coil extension 13Be.Step is subsequently carried out with described order, forms sweep thus on upper layer coil extension 13Be.

(advantageous effects of second embodiment)

Adopt the armature 14B of described current embodiment, sweep 13Bc is formed on the upper layer coil extension 13Be in bottom and place, the cross one another intersection region of upper layer coil extension 13Ae, 13Be.Therefore, between bottom and upper layer coil extension 13Ae, 13Be, can guarantee enough air gaps as insulation distance.In addition, the sweep 13Bc plastic deformation of upper layer coil extension 13Be becomes to follow the curved shape of shaped portion 56a shape, does not have insulation film to peel off.Therefore, do not need a large amount of insulation distances to be arranged between two upper and lower layer line circle extension 13Be, the 13Ae in bottom and upper layer coil extension 13Ae, X place, the cross one another intersection region of 13Be.This makes sweep 13Bc form minimum structure, causes the stress that acts on the upper layer coil extension 13Be to reduce.

Forming machine 30 shown in the employing, do not need the die-cut machine of working pressure to carry out the pressure die-cut operation in case with the corresponding zone of intersection region X in hold on coil extension 13Ae, the 13Be on bottom and top and to form stepped portion.Therefore, bottom and top are held coil extension 13A e, 13Be and are not had the burr that die-cut operation causes, and solve easily owing to the various problems that burr causes occurs.

In addition, be equipped with can be at the coil limit collar 32 of the position restriction upper layer coil extension 13Be that just extracts out from relevant stria 25 for forming machine 30.When the far-end 36a of upper layer coil extension 13B e by pressure punch 36 pressed, this structure prevented owing to its reaction makes upper layer coil extension 13Be float on radially outer direction.This makes upper layer coil extension 13Be and armature core 12 electrically contact (so that ground connection).

In addition, on it is axial, press armature shaft 11, moving axially of armature core 12 do not occur in the stage when working pressure drift 36 forms sweep 13Bc on upper layer coil extension 13Be because forming machine 30 is equipped with retention mechanism 44.That is, sweep 13B c can be formed on the upper layer coil extension 13Be, and wherein upper layer coil extension 13Be fixedly is confined to given axial location.Therefore, the sweep 13Bc shape that can follow the shaped portion 56a of forming jig 34 is formed on the upper layer coil extension 13Be in efficient and reliable mode.

In addition, have forming jig 34 and the insertion tongue 56 that coil inserts recess 54 owing to be provided with between adjacent wall surface 54a, 54a, upper layer coil extension 13Be can be confined to coil reliably and insert in the recess 54.Therefore, upper layer coil extension 13Be can be anti-to use under stable state, makes it form sweep 13Bc in highly reliable mode easily on upper layer coil extension 13Be.

In addition, the insertion tongue 56 of forming jig 34 has from inserting tongue 56 reduces its radial thickness gradually towards its far-end inclined lead wall.Operating process middle and upper part layer line circle extension 13Be when this causes the gap of inserting between tongue 56 insertion bottoms and upper layer coil extension 13Ae, the 13Be and the contact resistance that inserts between the tongue 56 reduce.This makes it insert bottom and upper layer coil extension 13Ae, 13Be easily so that insert tongue 56.

In addition, in the operating process that will insert the gap between tongue 56 insertion bottoms and upper layer coil extension 13Ae, the 13Be, lower layer coil extension 13Ae inserts in the annular guide space 62 between the neighboring of the inwall be limited to cylindrical hole 50a and Internal jigging 38, makes it can prevent that lower layer coil extension 13Ae from inwardly radially subsiding.

In addition, adopt forming machine 30, the far-end 36a that is used to press the pressure punch 36 of upper layer coil extension 13B e forms R shape.Adopt this structure, the far-end 36a of pressure punch 36 can have the minimum contact surface area with upper layer coil extension 13Be, and the insulation quality that reduces upper layer coil extension 13Be is degenerated.In addition, the stress that is formed on the far-end 36a that R shape on the far-end 36a on the pressure punch 36 can suppress pressure punch 36 is concentrated, and prevents from thus crackle or fragmentation to occur on the far-end 36a of pressure punch 36.In addition, adopt the width of the far-end 36a of pressure punch 36 wherein to be specified to structure greater than the circumferential width of upper layer coil extension 13Be, the far-end 36a of pressure punch 36 can press upper layer coil extension 13Be on its whole circumferential width, prevent that local deformation from appearring in upper layer coil extension 13Be and degenerating appears in insulation quality.

(modification of second embodiment)

Though had as the case description of the sweep 13Bc of profile crushed element current embodiment with reference to upper layer coil extension 13Be wherein, other selection form also is fine, can be so that lower layer coil extension 13Ae have the sweep as the profile crushed element, its shape is similar to the sweep 13Bc of upper layer coil extension 13Be.In another selection form, bottom and upper layer coil extension 13Ae, 13Be can have the sweep that is similar to sweep 13Bc respectively.

Though toply propose the forming machine 30 of current embodiment with reference to the structure that adopts single pressure punch 36, forming machine 30 can be constructed with the whole winding of forming jig 34 and insert the relevant a plurality of pressure punch 36 of recess 54.Adopt this selection form, sweep 13Bc can be formed on all upper layer coil extension 13Bc of upper coil 13B simultaneously, causes the efficient of shaping operation to increase.

Equally, the shaped portion 56a that inserts tongue 56 can change, and makes shaped portion 56a have and consider the shape that upper layer coil extension 13Be has a rebound and acts on when pressure punch 36 presses upper layer coil extension Be.

In addition, forming machine 30 can structurally change, so that make the neighboring of forming jig 34 form die-cut guide notch, so that pressure punch 36 is directed to given position.Adopt this selection form, can realize the location of pressure punch 36 easily, and the bending position of stable upper layer coil extension 13Be.

In addition, though top starter with reference to various embodiments is described electric rotary machine of the present invention, conclusive is except starter, and as required, electric rotary machine of the present invention is applicable to the another kind of machine of for example motor or alternating current generator.

Though describe specific embodiment of the present invention in detail, those skilled in the art will appreciate that multiple modification and the type selecting of developing these details under can the inspiration of general teachings disclosed here.Therefore, disclosed customized configuration refers to exemplary, and does not limit the scope of the invention, and scope of the present invention is provided by the full breadth of claims and equivalents thereof.

Claims

1. electric rotary machine comprises:

Be loaded with the yoke (9) of a plurality of permanent magnets (10) on it;

Be fixedly supported upon armature shaft (11) and go up the armature core (12) that also is arranged in rotationally in the yoke, it has the neighboring that forms a plurality of strias (25);

The armature coil of a plurality of coating insulators (13), this armature coil is wound in the stria of armature core with multilayer form, each coil comprises and is formed on bottom and upper layer coil (13A, 13B) Nei the flat wire rod in each stria with top and lower layer arranged in form; And

Commutator (15), commutator is fixedly supported upon on the armature shaft at one end place, and have in its a plurality of conductor section (15a) on equidistant neighboring that is arranged in armature shaft on circumferentially, conductor section comprises the riser (15b) that is electrically connected with bottom and upper layer coil respectively;

Its middle and lower part and upper layer coil (13A, 13B) comprise lower layer coil extension (13Ae) and the upper layer coil extension of extracting out from each stria of armature core (13Be), and at least one bottom and upper layer coil extension (13Ae, 13Be) comprise profile crushed element (13Bt) in the area that is formed on place, the cross one another intersection region of lower layer coil extension and upper layer coil extension, so as at lower layer coil extension and place, upper layer coil extension intersection region and between form insulation distance;

Profile crushed element (13Bt) is included in radially aduncate sweep (13Bc) in lower layer coil extension (13Ae) and the cross one another intersection region of upper layer coil extension (13Be), thereby is created in the insulation distance between lower layer coil extension (13Ae) and the upper layer coil extension (13Be).

2. electric rotary machine as claimed in claim 1 is characterized in that:

The riser of each stria has the riser stria of the far-end that holds the bottom that forms the upper and lower layer and upper layer coil extension therein, the far-end of its middle and lower part and upper layer coil extension has the apparent surface who covers insulation film respectively, this film melts by fusion, makes the mutual electric and mechanical bond of far-end of bottom and upper layer coil extension.

3. electric rotary machine as claimed in claim 1 is characterized in that:

The profile crushed element of at least one bottom and lower layer coil extension comprises the reverse part in the area that is formed on lower layer coil extension and the cross one another intersection region of upper layer coil extension.

4. electric rotary machine as claimed in claim 1 is characterized in that:

Lower layer coil extension is in the area of section that has the area of section that is substantially equal to lower layer coil extension before and after it in the area at lower layer coil extension and the cross one another intersection region of upper layer coil extension.

5. electric rotary machine as claimed in claim 1 is characterized in that:

The flat wire rod that is used for each armature coil forms by stretching step.

6. electric rotary machine as claimed in claim 3 is characterized in that:

The reverse part of at least one bottom and upper layer coil extension has the area of section that its main shaft tilts with given angle with respect to the main shaft of the area of section of another extension in bottom and the upper layer coil extension.

7. electric rotary machine as claimed in claim 1 is characterized in that:

The sweep of at least one bottom and upper layer coil extension comprises with curved shape and is formed on plastic deformation part at least one bottom and the upper layer coil extension.

8. armature that is used for electric rotary machine comprises:

Armature shaft;

Be fixedly supported upon on the armature shaft and be applicable to the armature core that rotates in electric rotary machine, it has the neighboring that forms a plurality of strias;

The armature coil of a plurality of coating insulators, armature coil are wound on multilayer form in the stria of armature core, each coil comprise be formed on top and lower layer arranged in form in each stria the bottom and the flat wire rod in the upper layer coil;

Commutator, this commutator is fixedly supported upon on the armature shaft at one end place, and has in its a plurality of conductor section on equidistant neighboring that is arranged in armature shaft on circumferentially, and conductor section comprises the riser that is electrically connected with bottom and upper layer coil respectively;

Its middle and lower part and upper layer coil comprise lower layer coil extension and the upper layer coil extension of extracting out from each stria of armature core, and at least one bottom and upper layer coil extension comprise the profile crushed element in the area that is formed on place, the cross one another intersection region of lower layer coil extension and upper layer coil extension, so as at lower layer coil extension and place, upper layer coil extension intersection region and between form insulation distance;

9. the armature that is used for electric rotary machine as claimed in claim 8 is characterized in that:

10. the armature that is used for electric rotary machine as claimed in claim 8 is characterized in that:

11. the armature that is used for electric rotary machine as claimed in claim 8 is characterized in that:

12. the armature that is used for electric rotary machine as claimed in claim 8 is characterized in that:

The flat wire rod that is used for each armature coil forms by stretching step.

13. the armature that is used for electric rotary machine as claimed in claim 10 is characterized in that:

14. the armature that is used for electric rotary machine as claimed in claim 8 is characterized in that:

15. a method of making electric rotary machine comprises:

Preparation is fixedly supported upon on the armature shaft and has the armature core of the neighboring that is formed with a plurality of strias and to be carried on commutator on the armature shaft with the aspectant relation of armature core, commutator comprises and circumferentially is placed on equally spaced locational a plurality of conductor section that conductor section has riser respectively;

In the stria of armature core, apply the coil of insulators, make coil that the upper and lower applies insulator be arranged in each stria in the mode of top and lower layer with reel a plurality of upper and lowers of multilayer mode;

The upper and lower applies the coil of insulator and extracts out from the stria of armature core as upper and lower layer line circle extension respectively;

The profile crushed element is formed at least one bottom and the upper layer coil extension in the area at lower layer coil extension and place, the cross one another intersection region of upper layer coil extension, so that form insulation distance between lower layer coil extension and upper layer coil extension; And

The far-end of bottom and upper layer coil extension is electrically connected on each riser of conductor section of commutator;

Wherein profile crushed element (13Bt) is included in radially aduncate sweep (13Bc) in lower layer coil extension (13Ae) and the cross one another intersection region of upper layer coil extension (13Be), thereby is created in the insulation distance between lower layer coil extension (13Ae) and the upper layer coil extension (13Be).

16. the method for manufacturing electric rotary machine as claimed in claim 15 is characterized in that:

17. the method for manufacturing electric rotary machine as claimed in claim 15 is characterized in that:

18. the method for manufacturing electric rotary machine as claimed in claim 15 is characterized in that:

19. the method for manufacturing electric rotary machine as claimed in claim 15 is characterized in that:

The flat wire rod that is used for each armature coil forms by stretching step.

20. the method for manufacturing electric rotary machine as claimed in claim 22 is characterized in that:

21. the method for manufacturing electric rotary machine as claimed in claim 15 is characterized in that:

22. a forming machine that is used for the armature of electric rotary machine, this armature have armature shaft, are fixedly supported upon on the armature shaft and are applicable to the armature core that rotates in electric rotary machine, it has the neighboring that forms a plurality of strias; The armature coil of a plurality of coating insulators is wound on multilayer form in the stria of armature core, each coil comprise be formed on top and lower layer arranged in form in each stria the bottom and the flat wire rod in the upper layer coil; Commutator is fixedly supported upon on the armature shaft at one end place, and has in its a plurality of conductor section on equidistant neighboring that is arranged in armature shaft on circumferentially, and conductor section comprises the riser that is electrically connected with bottom and upper layer coil respectively; Its middle and lower part and upper layer coil comprise lower layer coil extension and the upper layer coil extension of extracting out from each stria of armature core; At least one bottom and upper layer coil extension comprise in the area that is formed on place, the cross one another intersection region of lower layer coil extension and upper layer coil extension the profile crushed element in case at lower layer coil extension and place, upper layer coil extension intersection region and between form insulation distance; This forming machine comprises:

Operationally armature core is remained on the processing maintaining body on the given position;

Thereby can operate so that be placed on the neighboring of armature core the coil limit collar that upper layer coil extension is limited in just from the stage that the stria of armature core is extracted out;

Forming jig can be operated so that insert gap between the upper and lower layer line circle extension of extracting out from the stria of armature core, and comprise shaped portion so that form the profile crushed element at least one bottom and upper layer coil extension; And

Pressure punch can be operated so that shaped portion is pressed in the neighboring of at least one bottom and upper layer coil extension;

23. the forming machine that is used for the armature of electric rotary machine as claimed in claim 22 is characterized in that, also comprises:

Retention mechanism, this mechanism can operate so that press armature shaft on it is axial, so that armature shaft is positioned at given position, thereby prevents moving axially of armature core.

24. the forming machine that is used for the armature of electric rotary machine as claimed in claim 22 is characterized in that, it is characterized in that:

Forming jig comprises the insertion tongue that is applicable to the gap between the layer line circle extension of insertion upper and lower and is formed with shaped portion, shaped portion has the both sides that are formed with wall surface, between wall surface, form coil and insert recess, so that hold upper layer coil extension and it is remained on the fixed position.

25. the forming machine that is used for the armature of electric rotary machine as claimed in claim 24 is characterized in that, it is characterized in that:

Insert tongue and have the inclined lead wall that reduces radial thickness from the tip portion of shaped portion towards its distal portions.

26. the forming machine that is used for the armature of electric rotary machine as claimed in claim 22 is characterized in that, it is characterized in that:

Pressure punch has the far-end that forms R shape with respect to the longitudinal axis of upper layer coil extension, and has given width with respect to the Width of upper layer coil extension.

27. the forming machine that is used for the armature of electric rotary machine as claimed in claim 26 is characterized in that, it is characterized in that:

The width of pressure punch is defined as equaling or slightly greater than the width of upper layer coil extension.

28. the forming machine that is used for the armature of electric rotary machine as claimed in claim 22 is characterized in that, it is characterized in that:

Forming jig has the neighboring that is formed with the drift guide notch, so that pressure punch is directed on the given position on the upper layer coil extension.

29. the forming machine that is used for the armature of electric rotary machine as claimed in claim 22 is characterized in that, it is characterized in that:

Internal jigging is installed in the forming jig, so that the inner rim of restriction lower layer coil extension.