JP2018152938A - Dc motor provided with brush, and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a DC motor provided with a brush, that is capable of flexibly responding to needs of high precision and high reliability, while meeting needs for cost reduction, and to provide a manufacturing method of the same.SOLUTION: There is provided a DC motor comprising a magnet disposed on an inner circumferential side of a motor case, a rotor comprising an armature winding and a commutator, a pair of brushes sliding in contact with the commutator, and an end cap for holding a brush fixed at one end of the motor case. Provided are a first choke coil holding groove and a second choke coil holding groove each provided between the pair of brushes on a surface side of an end cap body. A first terminal slit and a second terminal slit are provided at positions sandwiching the first choke coil holding groove; a third terminal slit and a fourth terminal slit are provided at positions sandwiching the second choke coil holding groove; and planar shapes of the first terminal slit, the second terminal slit, the third terminal slit, and the fourth terminal slit are identical to each other.SELECTED DRAWING: Figure 3A

Description

  The present invention relates to a brushed DC motor and a method for manufacturing the same.

Brushed DC motors are widely used in various fields as drive sources for devices constituting various control systems, and their applications are expanding. For example, DC motors with brushes are used as motors for opening and closing valves in automobile engine intake systems and exhaust systems, power seats, drive sources for opening and closing windows, trunks, and back doors.
The DC motor with a brush performs rectification with a commutator using a brush, and electromagnetic noise is generated by a spark generated when the commutator and the brush come into contact with each other during rectification. In addition, noise due to the influence of the inductance of the armature coil is also generated during rectification. Depending on the environment in which the direct current motor is mounted, a noise prevention circuit is attached to the direct current motor as a countermeasure against noise in these wide frequency bands.

  Regarding DC motors for in-vehicle use, in order to eliminate the adverse effects on other electric components such as in-vehicle engine controllers, the regulation of the allowable value of noise generated by brushes is defined as EMC (electric magnetic compatibility) standards. It is regulated internationally.

As a DC motor having a noise prevention circuit, Patent Document 1 discloses that a choke coil and a capacitor are installed in a brush holder, and noise generated in a power supply circuit is absorbed by a choke coil. A relatively low frequency is absorbed by a capacitor.
Further, in Patent Document 2, as a noise prevention circuit compliant with the EMC standard, a choke coil is provided on the front side facing the armature of the brush plate and a capacitor (corresponding to common mode) is provided on the back side thereof. The thing connected via the insert terminal provided in the side is disclosed. The choke coil is fixed along the surface side of the end cap body.
Further, Patent Document 3 discloses a DC motor in which a printed circuit board on which a noise prevention circuit is mounted is provided on an end cap.

JP 2004-56894 A JP2015-70658A JP 2008-178249 A

As a direct current motor for automobiles, a two-pole brushed permanent magnet type DC motor (hereinafter referred to as a brushed direct current motor) that has the same torque characteristics in both forward and reverse rotations, taking advantage of its small size and low price. Many have been adopted.
Control systems are becoming smaller and lighter due to the need for low fuel consumption and low cost of automobiles. In addition, the control system is required to have higher accuracy and higher reliability due to stricter environmental regulations. There is also a need for improved safety / comfort. For example, as a new electronic control device is installed in a trunk room where noise countermeasures were initially unnecessary, a motor with a noise prevention function may be required. Alternatively, in order to provide a more comfortable environment when a user uses an electronic device such as an audio device in a vehicle interior, a motor with a higher noise prevention function may be required.

On the other hand, depending on the installation environment of the DC motor, there is a place where a noise prevention circuit is usually not required, such as a trunk opening / closing motor. In such places, a DC motor without a noise prevention circuit is adopted from the viewpoint of priority on low fuel consumption / cost reduction.
The DC motor manufacturer needs to respond flexibly to these various requirements.

  The conventional DC motor with brushes is a non-EMC motor that prioritizes low fuel consumption and cost reduction, and a noise prevention circuit that complies with the EMC standard considering high accuracy and high reliability. Are separately designed and manufactured.

The inventions described in Patent Document 1 to Patent Document 3 do not fully consider the needs for low fuel consumption / cost reduction and the needs for high accuracy / high reliability and safety / comfort improvement.
For example, the invention described in Patent Document 1 has a choke coil installed in a direction parallel to the motor axis, and the overall shape of the brush holder is large, which is not suitable for satisfying the demand for low fuel consumption / cost reduction. .
In addition, the invention described in Patent Document 2 is provided with an EMC standard-compliant noise prevention circuit across both sides of the brush plate, but the connection circuit between the components of the noise prevention circuit and the terminals becomes complicated. Not suitable for meeting the demands of low fuel consumption / cost reduction.
Further, the invention described in Patent Document 3 is configured to connect an end cap and a printed circuit board on which a noise prevention circuit is mounted, and is not suitable for satisfying the demand for low fuel consumption / cost reduction.
In addition, none of the patent documents discloses a sufficient measure for flexibly responding to various requirements for a DC motor.

One of the problems to be solved by the present invention is to provide a brushed DC motor that can flexibly meet the needs for high precision and high reliability while meeting the needs of low fuel consumption / cost reduction, and a method for manufacturing the same. There is to do.
Another object of the present invention is to provide a brushed DC motor that can flexibly cope with an unexpected change in specifications such as a demand for improvement in safety / comfort, and a method for manufacturing the same.

According to one aspect of the present invention, a magnet disposed on the inner peripheral side of the motor case, a rotor having an armature winding and a commutator, a pair of brushes slidably in contact with the commutator, and the motor case In a direct current motor having an end cap fixed to one end and holding the brush, the end cap is provided at an opposite position on the surface side of the end cap body and the end cap body, and the pair of brushes A pair of brush holder holding portions to be held, first to fourth terminal / terminal slits provided near the outer edge of the end cap body and penetrating from the front surface side to the back surface side of the end cap body, and the end cap A first choke coil holding groove and a second choke coil holding groove respectively provided between the pair of brushes on the surface side of the main body, The first and second terminal / terminal slits are at positions sandwiching the first choke coil holding groove, and the third and fourth terminal / terminal slits are at positions sandwiching the second choke coil holding groove. Yes, the planar shapes of the first to fourth terminals and terminal slits are the same.
As a result, the end cap can be used for either DC motors that do not comply with EMC standards and that do not support EMC, and respond flexibly to needs for higher accuracy and higher reliability while meeting the need for cost reduction. A brushed DC motor can be provided.

  According to another aspect of the present invention, each of the first to fourth terminal / terminal slits includes a slit portion and a claw receiving portion extending radially from both sides of the slit. As a result, the end cap can be used for any DC motor that conforms to the EMC standard and does not conform to EMC, and can meet the need for cost reduction.

  According to another aspect of the present invention, the end cap body includes at least one capacitor holding portion on the surface of the end cap body and radially outward from the choke coil holding grooves, respectively. At least one resistance holding unit is provided. As a result, it is possible to respond flexibly to various levels of noise countermeasures while meeting the need for cost reduction.

According to another aspect of the present invention, a power supply terminal and a relay terminal corresponding to each of the terminals and terminal slits are provided, and the power supply terminal includes a connection terminal, a stepped portion, a fixing claw portion, and a terminal terminal. The relay terminal includes a connection terminal, a stepped portion, a fixing claw portion, and an insertion portion, and the terminal terminal of the power supply terminal and the insertion portion of the relay terminal are formed of the terminal / terminal slit. The fixed claw part of the power terminal and the fixed claw part of the relay terminal have the same cross-sectional shape that can be inserted into the claw receiving part. .
As a result, it is possible to provide a brushed DC motor that can respond to needs for high accuracy and high reliability while meeting the need for cost reduction by properly using the power terminal and the relay terminal.

  According to another aspect of the present invention, the end cap is constituted by the end cap body and a shield cap, and the shield cap is a bearing corresponding to a boss portion provided at a central portion of the end cap body. It has a holding part. Thereby, it is possible to provide a brushed DC motor having a function of suppressing radiation noise while meeting the need for cost reduction.

According to another aspect of the present invention, in a DC motor with a brush, a first brush and a second brush constituting the pair of brushes, a first relay terminal corresponding to the first brush, and a first brush A second relay terminal and a second power terminal corresponding to the second brush, wherein the first brush is connected to a connection terminal of the first relay terminal, The second brush is connected to the connection terminal of the second relay terminal, the first relay terminal is fixed to the first terminal / terminal slit, the third terminal / terminal slit, The second relay terminal is fixed, the connection terminal of the first power supply terminal is connected to the second terminal / terminal slit, and the second power supply terminal is connected to the fourth terminal / terminal slit. of Connection terminals are connected.
Accordingly, it is possible to provide a DC motor that complies with the EMC standard while meeting the need for cost reduction.

According to another aspect of the present invention, in a DC motor with a brush, the brush comprises a first brush and a second brush that constitute the pair of brushes, and the first brush is used for connecting a first power supply terminal. Connected to a terminal, the second brush is connected to a connection terminal of a second power terminal, the first power terminal is fixed to the first terminal / terminal slit, the third terminal, The second power supply terminal is fixed to the terminal slit.
As a result, it is possible to provide a non-EMC direct current motor while meeting the need for cost reduction.

  According to another aspect of the present invention, a second condenser holding portion is provided on the back surface of the end cap body, the second condenser is fixed to the second capacitor holding portion, and the end cap body is in communication. The second capacitor and the pair of power supply terminal connection terminals are connected by wiring through the communication hole. As a result, it is possible to provide an EMC standard-compliant brushed DC motor that can meet the needs for further improvements in safety / comfort, which is compatible with the common mode and normal mode, while meeting the needs for cost reduction.

According to another aspect of the present invention, there is provided a method for manufacturing a brushed DC motor, wherein the brushed DC motor includes a magnet disposed on an inner peripheral side of a motor case, an armature winding, and a commutator. The motor case, the magnet, and the rotor, each including a rotor, first and second brushes that are in sliding contact with the commutator, and end caps that are fixed to one end of the motor case and hold the brushes. Each of the first and second brushes and the end cap is a configuration common to a DC motor with a noise countermeasure circuit and a DC motor without the noise countermeasure circuit. On the surface side of the end cap body, each has a pair of brush holder holding portions, a choke coil holding groove, a groove portion for resistance connection, and a groove portion for capacitor connection, A step of preparing a standard end cap structure having first to fourth terminals and terminal slits penetrating from the front surface side to the back surface side of the end cap main body in the vicinity of the outer edge of the end cap main body, and a relay terminal, Fixing the first and third terminals and terminal slits by sandwiching from both sides of the end cap body; and the second and fourth terminals by sandwiching the power terminal from both sides of the end cap body. A step of fixing to the terminal slit; a step of holding the first and second brushes on the brush holder holding portion; and the first and second brushes respectively via the relay terminals. Connecting to the power terminal and connecting the anti-noise circuit between the relay terminal and the power terminal, the first and second terminals Terminal slit is at a position sandwiching the first choke coil retaining grooves, said third and fourth slits for terminal pin is at a position sandwiching the second choke coil retaining grooves.
As a result, it is possible to provide an EMC standard-compliant brushed DC motor that can meet the needs for higher accuracy and higher reliability while meeting the need for cost reduction.

According to another aspect of the present invention, in the DC motor manufacturing method, each of the power supply terminal and the relay terminal has a step portion and a fixed claw portion, and the step portion is formed on the surface of the end cap body. Then, by pressing the fixing claw portion from the back side of the end cap body, the power terminal and the relay terminal are fixed to the end cap body so as to sandwich both surfaces of the end cap body.
As a result, it is possible to provide a brushed DC motor that can respond to needs for high accuracy and high reliability while meeting the need for cost reduction by properly using the power terminal and the relay terminal.

According to another aspect of the present invention, in the method of manufacturing a direct current motor, the standard end cap structure is provided for resistance connection on the surface side of the end cap body and radially outward of the choke coil holding groove. A groove portion and a groove portion for connecting a capacitor, and a choke coil is connected between the connection terminal of the relay terminal and the power supply terminal on the surface side of the end cap body, and the choke One end of a resistor and a capacitor is connected to a terminal on the power supply terminal side of the coil, and the other end of the resistor and the capacitor is connected to the motor case.
As a result, it is possible to provide an EMC standard-compliant brushed DC motor that can meet the needs for higher accuracy and higher reliability while meeting the need for cost reduction.

According to another aspect of the present invention, in the DC motor manufacturing method, the standard end cap structure has a second capacitor holding portion on the back surface side of the end cap body, and the front surface of the end cap body. And a communication hole that communicates between the back surface, the second capacitor is fixed to the second capacitor holding portion, the power terminal and the relay terminal on the surface side of the end cap body, and the second A condenser is connected with the conductor through the communication hole.
As a result, it is possible to provide an EMC standard-compliant brushed DC motor that can meet the needs for further improvements in safety / comfort, which is compatible with the common mode and normal mode, while meeting the needs for cost reduction.

According to the present invention, based on a basic standard motor with high versatility, a brushed DC that can meet the needs of low fuel consumption / cost reduction by realizing motor applications according to various applications. A motor and a method for manufacturing a DC motor can be provided.
In addition, according to the present invention, based on a standard motor with an end cap of a common configuration, it contributes to the progress of electronic control and further improvement of safety / comfort, and flexible to unexpected specification changes It is possible to provide a brushed DC motor and a method for manufacturing the same.

It is a figure which shows an example of the component group by which the DC motor was standardized based on one Embodiment of this invention. It is a figure which shows the example of the variation of the direct current motor classified by use implement | achieved combining the standardized component group shown to FIG. 1A. 1 is a longitudinal sectional view of a DC motor showing an example to which the present invention is applied. FIG. 3 is a front view of an end cap of the DC motor of FIG. 2 according to an embodiment of the present invention. 3B is a side view of the end cap shown in FIG. 3A. FIG. FIG. 3B is a rear view of the end cap shown in FIG. 3A. It is a perspective view of a power terminal and a relay terminal in one embodiment of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing an end cap portion of an EMC standard compliant DC motor according to a first example to which an embodiment of the present invention is applied. It is a reverse view of the end cap part of the direct-current motor which becomes a 1st Example. It is a power supply circuit diagram of the DC motor which becomes a 1st Example. It is a perspective view which shows the part of an end cap of the DC motor non-compliant with the EMC standard, which is a second example to which an embodiment of the present invention is applied. It is a reverse view of the end cap part of the DC motor which becomes a 2nd Example. It is a longitudinal cross-sectional view of the DC motor corresponding to the EMC standard, which is a third example to which an embodiment of the present invention is applied. It is a front view of the end cap of the DC motor in the third embodiment. FIG. 11B is a side view of the end cap shown in FIG. 11A. FIG. 11B is a rear view of the end cap shown in FIG. 11A. It is a perspective view of the shield cap in a 3rd Example. It is a rear view of the end cap part of the DC motor corresponding to the EMC standard (common mode and normal mode), which is a fourth example to which an embodiment of the present invention is applied. FIG. 14 is a power circuit diagram of the EMC standard compliant DC motor of FIG. 13.

Embodiments of a DC motor according to the present invention will be described below with reference to the drawings.
[Standardization of DC motor]
FIG. 1A shows an example of a standardized group of components of a DC motor according to an embodiment of the present invention.
The brushed DC motor 100 includes, as its constituent elements, a cup-shaped metal motor case 12 that is commonly used for all variations of the motor, and a two-pole magnet 14 disposed on the inner peripheral side of the motor case. And an end cap (standard end cap structure) 16 for holding the brush terminal structure 17.

The magnet 14 has different characteristics depending on the motor output, for example, two sets of variations. That is, either the dry magnet 141 or the wet magnet 142 is employed, and the stator is configured by being pressed and fixed to the inner peripheral side of the motor case by the magnet holder 143. Furthermore, the flux ring 11 is fixed to the outer periphery of the motor case 12 as necessary. The flux ring 11 is provided to improve the efficiency of the motor 100 by suppressing magnetic flux from leaking from the outer peripheral surface of the motor case.
The rotor 15 has an armature winding and a commutator. As winding specifications, there are two sets of variations: a rotor without skew 151, and a rotor with skew 152 when it is necessary to reduce electrical vibration and noise.
The bearing 13 holds the shafts at both ends of the rotor 15 in the motor case 12, and there are two sets of variations, a ball bearing and a sleeve bearing. Depending on the application of the motor, ball bearings 131 and 135, or sleeve bearings 132, 133, and 134 are employed. Each of the motor case 12 and the standard end cap structure 16 includes a boss portion that can be installed by any of the variations of the bearers. Reference numeral 121 denotes a collar which is installed at both ends of the sleeve bear 132. Either a single ball bearing or a double ball bearing can be selected as the ball bearing.

In addition, the standard end cap structure (which may be simply referred to as an end cap) 16 has a main body portion made of an insulating resin mold, and the material thereof includes, for example, polyamide 66 and polyamide 46 in consideration of heat resistance. is there. There are standard end cap structures 16 with or without EMC, and there are also shield caps with higher noise resistance, and there are, for example, four sets of variations as a whole. That is, the standard end cap structure 16 is an end cap (integrated type) 161 and an EMC standard-compliant noise prevention circuit 19 (present, no), an end cap (divided type) 163 and an EMC standard-compliant noise prevention circuit 19 (present). ), And an EMC standard-compliant noise prevention circuit 19 (common mode and normal mode) 164.
The end cap (integrated type) 161 is integrally formed with a boss portion for holding the bearing on the back side of the end cap body. The end cap (split type) 163 has a structure in which a shield cap 18 having a bearing holding boss portion is fixed to the back side of the end cap body. The metal shield cap 18 is fixed to the metal motor case 12 and has a function of suppressing radiation noise. However, in any of the variations, the end cap main body is common in the configuration of the surface side and the side surface facing the rotor.

The brush terminal structure 17 basically includes a pair of brushes that are in sliding contact with the commutator and a pair of brush holders that are fixed to one end (opening end) of the motor case and face each other. It is. However, the structure of the member attached to the standard end cap structure 16 differs depending on whether or not the EMC standard is supported.
[Variations of standardized DC motors]

By combining the standardized DC motor components shown in FIG. 1A, a variation of the DC motor as shown in FIG. 1B can be obtained. For example, the DC motors 100A to 100F can be obtained depending on the presence / absence of EMC standards, the presence / absence of shield caps (radiation noise suppression), the presence / absence of EMC standards (common mode and normal mode), and the presence / absence of high temperature / high torque.
[Standardized DC motor components]

Hereinafter, examples of a standardized component group of a DC motor according to an embodiment of the present invention will be described in detail.
FIG. 2 is a longitudinal sectional view showing an example of a DC motor according to an embodiment of the present invention. The motor case 120 of the DC motor 100 is a metal case such as iron that has a boss portion 124 at one end side 123 and is open at the other end side. An end cap body 1610 made of an insulating resin is provided as an end cap structure 161 that closes the other end of the motor case 120.
In the present invention, the surface (inner surface) 1613 facing the rotor 15 of the end cap body 1610 is defined as the surface of the end cap body, and the opposite surface (outer surface) is defined as the back surface of the end cap body.

The rotor 1520 includes a shaft 1511 and a commutator 1512, and one end of the shaft 1511 is rotatably supported by the boss portion 124 via a bearing 131. The other end of the shaft 1511 is supported by a boss portion 1612 provided at the center of the end cap body 1610 via a bearing 133. By electrically connecting the armature winding of the rotor 1520 to the commutator 1512, the commutator 1512 and the armature winding constitute the rotor 15 of the motor. The DC motor 100 further includes a pair of brushes 174 that are in sliding contact with the commutator 1512 and a brush holder that slidably holds the brushes 174. The brush holder is held by a brush holder holding portion formed on the surface of the end cap body 1610. Terminals connected to the brushes 174 via pigtails 173 are provided in the vicinity of the radially outer edge of the end cap body 1610. These terminals are terminal terminals 171-1 extending to the back side of the end cap body 1610, 171-2. The brush holder 172 can be made of insulating resin or metal.
A driven member is connected to one end of the shaft 1511 directly or via a gear.

  Next, the configuration of the end cap 161 will be described in detail. As shown in FIGS. 3A to 3C, the end cap 161 includes an end cap body 1610, a hole 1611, and a boss portion 1612 for holding a bearing. The end cap 161 further includes first and second brush holder holding portions 1614 that are formed at opposing positions on the surface 1613 of the end cap body and hold a pair of opposing brushes.

On both sides of each brush holder holding portion 1614 of the end cap body 1610, first to first surfaces penetrating from the surface side facing the rotor 15 of the end cap body to the back surface side at equal distances from the center of the end cap body. Fourth terminal / terminal slits 1616-1 to 1616-4 are provided. The plane shapes (the shapes shown in the front view of FIG. 3A and the rear view of FIG. 3C) of the first to fourth terminals and terminal slits are the same.
That is, each terminal / terminal slit 1616 includes, for example, a rectangular slit portion 1633 constituting an intermediate portion thereof, and claw receiving portions 1631 and 1632 extending radially inward (or outward) at both ends of the slit portion. The slit portion 1633 in the middle portion extends in a straight line from the center of the end cap body 1610 in a direction in contact with the arc at an equal distance. The plane shape of each terminal / terminal slit needs to correspond to the function of fixing both the power terminal 170A and the relay terminal 170B to the end cap body, but the specific shape is the cross-sectional shape of the power terminal. You may decide in consideration of.

Further, on the surface 1613 of the end cap body, there are two brush presser spring holding portions 1615, choke coil holding grooves 1617, capacitor holding portions 1618, resistance holding portions 1619, and spring pressers 1620 corresponding to a pair of brushes, respectively. The set is provided at the position of the axis target. The condenser holding portion 1618 and the resistance holding portion 1619 are formed outside the choke coil holding groove 1617.
That is, one choke coil holding groove is formed so as to extend along the surface 1613 of the end cap body on the surface side of the end cap body and between the first and second terminal / terminal slits 1616-1 and 1616-2. 1617 is formed, and the other choke coil holding groove 1617 extends between the third and fourth terminals / terminal slits 1616-3 and 1616-4 along the surface 1613 of the end cap body. Is formed. In other words, the terminals and terminal slits are provided on the surface 1613 of the end cap body on the side near the brush holder holding portions 1614 and without the brush pressing spring.

When the noise prevention circuit includes a plurality of capacitor elements (corresponding to the common mode) having different capacitances and a plurality of resistance elements having different resistance values, the capacitor holding unit 1618 and the resistance holding unit 1619 also include the plurality of elements. It is comprised with the some holding | maintenance part corresponding to. Hereinafter, an example of the capacitor holding unit 1618 corresponding to one element and the resistance holding unit 1619 corresponding to one element will be described.
Reference numeral 1625 denotes a communication hole for forming a spring presser. Reference numeral 1626 denotes a notch for crimping the terminal and the terminal. Reference numeral 1627 denotes a resistance connecting groove, 1628 denotes a capacitor connecting groove, and 1629 denotes a rotation stopper. Reference numeral 1635 denotes an outer edge of the end cap body, which is fixed to the opening of the motor case 120.

Next, the structure of the power supply terminal and the relay terminal in one embodiment of the present invention will be described with reference to FIG. 4A shows a power supply terminal 170A, and FIG. 4B shows a relay terminal 170B. The connection terminal 176 (176-1, 176-2) of the power terminal 170A and the connection terminal 179 (179-1, 179-2) of the relay terminal 170B are both connected to pigtails, etc. Have the same shape.
Both the power supply terminal 170A and the relay terminal 170B have a stepped portion 178 that functions as a stopper in the middle in the longitudinal direction, and fixed claw portions 177 are provided on both sides of the stepped portion.

The terminal terminals 171-1 and 171-2 at the tip of the power terminal 170A are inserted into the slit portion 1633 of the terminal / terminal slit 1616 of the end cap body 1610. Then, the fixed claw portion 177 is inserted through the claw receiving portions 1631 and 1632, and the fixed claw portion 177 is pressed from the back surface side of the end cap main body 1610 so as to sandwich the end cap main body between the stepped portion 178 of the terminal 170 A. Thus, the power terminal 170A is fixed to the end cap body 1610.
Similarly, in the relay terminal 170B, the central insertion portion 1715 is inserted into the slit portion 1633 of the terminal / terminal slit 1616, and the fixed claw portion 177 at the end of the stepped portion 178 inserted through the claw receiving portions 1631 and 1632 is ended. The relay terminal 170 </ b> B is fixed to the end cap body 1610 by being pressed against the end cap body from the back side of the cap body 1610.
Both the power terminal 170 </ b> A and the relay terminal 170 </ b> B are fixed to the terminal / terminal slit 1616. Therefore, both the terminal portion 171 of the power terminal 170A and the insertion portion 1715 of the relay terminal 170B have the same cross-sectional shape that can be inserted into the slit portion 1633 of the terminal / terminal slit 1616, for example, rectangular. Further, the fixed claw portion 177 of the power terminal 170A and the fixed claw portion 177 of the relay terminal 170B can be inserted into the claw receiving portions 1631 and 1632 of the terminal / terminal slit 1616, for example, the same cross-sectional shape, for example, rectangular. have.
[Variation of noise suppression circuit]

As a noise suppression circuit for a DC motor of the present invention, there is a “standardized noise suppression circuit” corresponding to a standard end cap structure described later (see FIGS. 7 and 14). In an actual product, necessary filter circuit components may be added or deleted based on a standardized noise countermeasure circuit according to the frequency band that requires countermeasures.
For example, (1) a circuit in which only the choke coil is connected between the terminals 171-1 and 171-2, (2) a circuit in which only the first capacitor is connected to the power supply terminal side of each choke coil, (3 ) A circuit in which only a resistor is connected to the power supply terminal side of each choke coil may be employed. Alternatively, (4) instead of a pair of choke coils, a second capacitor is connected between the terminals 171-1 and 171-2, and a capacitor and a resistor are connected to the power supply terminal side of the second capacitor. A circuit (see FIG. 7) may be employed. You may employ | adopt the circuit which deleted the choke coil from the circuit of FIG. The number and capacity of capacitors, the number of resistors, and the resistance value may be appropriately selected. In any case, by combining the standard end cap structure, it is possible to flexibly meet various requirements while reducing the cost.

  Hereinafter, an embodiment of a DC motor to which the standardized DC motor component group according to the present invention is applied will be described in detail.

First, as a first example to which an embodiment of the present invention is applied, a configuration example of a DC motor corresponding to the DC motor 100B of FIG. 1B will be described with reference to FIGS.
FIG. 5 is a perspective view showing an end cap portion of the EMC standard compliant DC motor according to the first embodiment, FIG. 6 is a rear view of the end cap, and FIG. 7 is a power supply circuit diagram.
The first brush 174 in the upper center of the figure and the second brush 174 in the lower center of the figure are each pressed toward the commutator 1512 by the brush pressing spring 175 held by the brush pressing spring holding portion 1615. The first brush 174 is connected to the connection terminal 179-1 of the relay terminal 170B via the pigtail 173, and an insertion portion 1715 of this connection terminal is inserted into the first terminal / terminal slit 1616-1. . The relay terminal 170B is formed by pressing the fixing claw portion 177 from the back side of the end cap body 16 in a state where the stepped portion 178 of the relay terminal 170B is in contact with the bottom of the surface of the end cap body 1610. The both ends are fixed to the end cap body.

  An EMC standard-compliant noise prevention circuit 19 is incorporated on the surface of the end cap body of the end cap 161. That is, one end of the choke coil 191 is connected to the connection terminal 179-1 of the relay terminal 170B. The other end of the choke coil 191 is connected to the connection terminal 176-1 of the first power terminal 170A fixed to the second terminal / terminal slit 1616-2. A first capacitor 193 (common mode) and a resistor 194 are connected to the connection terminal 176-1 via wirings 195a and 196a, respectively. The terminal terminal 171-1 of the first power supply terminal 170A is fixed to the end cap body by pressing the fixing claw portion 177 from the back surface side of the end cap body so as to sandwich both surfaces of the end cap body 1610 (see FIG. 6). The end of the wire 195b connecting the ground side of the first capacitor 193 to the motor case 120 is in the groove portion 1628 for connecting the capacitor, and the end of the wire 196b connecting the ground side of the resistor 194 to the motor case 120 is for connecting the resistor. The grooves 1627 are connected to each other.

The electrical connection between the connection terminal 176-1 of the terminal 170A, the other end of the choke coil 191, the first capacitor 193 (common mode) and the resistor 194 is performed by connecting each wiring portion to the inside of the connection terminal 176-1. After being collected and caulked, they are integrated by spot welding or the like.
Similarly, the second brush 174 in the lower center of FIG. 5 is connected to the connection terminal 179-2 of the relay terminal 170B via the pigtail 173, and one end of the choke coil 192 is connected to the connection terminal 179-2. Is connected. The other end of the choke coil 192 is connected to the connection terminal 176-2 of the second power supply terminal 170B fixed to the terminal / terminal slit 1616-4. A first capacitor 193 (common mode) and a resistor 194 are also connected to the connection terminal 176-2. After the respective wiring portions are gathered inside the connection terminal 176-2 and caulked, spot welding or the like is performed. These are integrated and electrically connected.

  The connection terminal P1 shown in the power supply circuit diagram of FIG. 7 corresponds to the connection terminal 179-1, and the connection terminal P2 corresponds to the connection terminal 179-2. The terminals P3 and P4 connected to the positive terminal and the negative terminal of the battery correspond to the terminal terminals 171-1 and 171-2. Further, the connection terminals P5 to P18 correspond to connection terminals 176-1 and 176-2, and the connection terminals P9 to P10 correspond to terminations of wirings 195b and 196b connected to the motor case 120.

  In this embodiment, the standard end cap structure 161 is a structure that can be used for a DC motor that does not support EMC, and the cost can be reduced by using the standard end cap structure 161 also.

  In addition, the entire components of the noise prevention circuit 19 compliant with the EMC standard are incorporated on the front side of the end cap body 1610. That is, the front side of the end cap body 1610 of the standard end cap structure has a structure as a substrate on which the entire components of the noise prevention circuit can be mounted. Furthermore, the terminal connection terminal and the relay terminal connection terminal are configured in common. By adopting these configurations, sharing of parts and standardization of work can be promoted. As a result, while maintaining a compact and lightweight configuration, it is possible to incorporate a noise prevention circuit to meet the needs of low fuel consumption / cost reduction, high precision / high reliability, and safety / comfort improvement. Can do.

  As described above, according to the present embodiment, it is possible to provide a brushed DC motor that can meet various needs such as high accuracy and high reliability while meeting the needs of low fuel consumption / cost reduction.

Next, as a second example to which an embodiment of the present invention is applied, a configuration example of a DC motor not corresponding to the EMC standard corresponding to the DC motor 100A of FIG. 1B will be described with reference to FIGS. explain. FIG. 8 is a perspective view showing a portion of the end cap of the DC motor, and FIG. 9 is a rear view of the end cap portion.
The first brush 174 at the upper center of FIG. 8 is connected to the connection terminal 176-1 of the first power supply terminal 170A via the pigtail 173. The lower second brush 174 is also connected to the connection terminal 176-2 of the second power supply terminal 170B via the pigtail 173. The first power terminal 170A is fixed to the terminal / terminal slit 1616-1, and the second power terminal 170B is fixed to the terminal / terminal slit 1616-3. The terminal terminals of the power terminals 170A and 170B are both fixed to the end cap body by pressing and fixing the fixing claw portion 177 from the back side with the stepped portion 178 in contact with the front side of the end cap body.
The terminal terminal 171-1 of the first power terminal 170A corresponds to the terminal P3 shown in the power circuit diagram of FIG. 7, and the terminal terminal 171-2 of the second power terminal 170B corresponds to the terminal P4.

  When a filter circuit in which the choke coil is removed is used as the noise prevention circuit, a filter circuit may be connected between the power supply terminals 170A and 170B and the motor case (earth).

In this embodiment, not only a basic structure such as a motor case and a rotor but also a standard end cap structure 161, a terminal terminal, a relay terminal, and the like can be shared with an EMC standard compliant DC motor. By doing so, the cost can be reduced. In particular, the front side of the end cap body 1610 of the standard end cap structure has a structure that functions as a substrate on which the entire components of the noise prevention circuit can be mounted, thereby maintaining a compact and lightweight configuration. Even if the end cap main body 1610 is directly adopted in a DC motor that does not comply with the EMC standard, it does not cause an increase in cost and can satisfy the needs of low fuel consumption and cost reduction.
As described above, according to the present embodiment, a brushed DC motor that can meet the needs of low fuel consumption / cost reduction can be provided.

Next, a brushed DC motor to which a shield function against electromagnetic noise is added will be described as a third example to which an embodiment of the present invention is applied. The direct current motor with brush of the present embodiment is provided with a metal shield cap 18 that removes radiation noise caused by contact between the commutator and the brush at the time of rotation through a motor case 120 that functions as a ground. .
FIG. 10 is a longitudinal sectional view of a non-EMC-compatible DC motor 100 according to the third embodiment. The standard end cap structure 163 of this embodiment is divided into an end cap body 1610 and a shield cap 18.

11A to 11C show the configuration of the end cap 163 of the DC motor in the third embodiment. As shown in FIG. 11A, the configuration of the end cap body 1610 is the same as the configuration of the end cap body 1610 of the first and second embodiments except for the central boss portion and the bearing holding structure. That is, as apparent from FIGS. 11B and 11C, the end cap body 1610 of the third embodiment does not have the bearing holding portion 1612 of the first and second embodiments.
Instead, a bearing holding portion is formed between the boss portion 1612 of the end cap body 1610 and the shield cap 18. That is, as shown in FIG. 12, the shield cap 18 has a bearing holding portion 1815 in its main body 1810. The bearing holding portion 1815 has a bearing holding claw 1814 around a central hole 1813. Reference numerals 1801 and 1802 denote notch portions through which the terminal terminals 171-1 and 171-2 pass, and reference numerals 1812 and 1816 denote positioning portions for fixing the shield cap body 1810 to the motor case 120.

In this embodiment, the standard end cap structure 163 can be used for either a non-EMC-compatible DC motor (corresponding to the DC motor 100C in FIG. 1B) or an EMC standard-compliant DC motor (corresponding to the DC motor 100D in FIG. 1B). The cost can be reduced by using the standard end cap structure.
Further, the configuration of the main part of the end cap body 1610 is the same as the configuration of the main part of the end cap body 1610 of the first and second embodiments, and costs can be reduced by standardizing parts and making the manufacturing process common. .

  Furthermore, in addition to the EMC standard compliant function, a radiation noise suppression function has been added to meet the needs for high accuracy, high reliability, and improved safety / comfort while meeting the needs for low fuel consumption / cost reduction. A DC motor that can be used can be provided.

Next, another example of an EMC standard compliant DC motor (corresponding to the DC motor 100D in FIG. 1B) will be described as a fourth example to which an embodiment of the present invention is applied.
FIG. 13 is a rear view of the end cap 164 of the EMC standard-compliant DC motor 100. FIG. 14 is a power supply circuit diagram of the DC motor 100. In this embodiment, terminals P3 and P4 are connected to the positive terminal and the negative terminal of the battery. A second capacitor 197 corresponding to the normal mode is connected between the pair of choke coils 191 and 192 via connection terminals P11 and P1. These connection terminals P11 and P12 correspond to the connection terminals 176 (176-1, 176-2) of the power supply terminals 170A, 170B in FIG. A second capacitor holding portion 199 is provided on the back surface of the standard end cap structure 1610, and the second capacitor 197 is fixed thereto. A wiring 198 connecting the second capacitor 197 and the connection terminals 176 of the power supply terminals 170A and 170B connects between the front surface and the back surface of the standard end cap structure 1610 through the two communication holes 1625. The outside of the end cap 164 is covered with a shield cap 18.

  In this embodiment, the standard end cap structure 164 can be used for either a non-EMC-compatible DC motor (corresponding to the DC motor 100C in FIG. 1B) or an EMC standard-compliant DC motor (corresponding to the DC motor 100D in FIG. 1B). The cost can be reduced by using the standard end cap structure.

Next, a high-temperature, high-torque DC motor will be described as a fifth example to which an embodiment of the present invention is applied. In this embodiment, the shape of the standard end cap structure is the same as that of Embodiments 1 to 4. The brush holder 172 held by the standard end cap structure is made of metal, and further, the material of the standard end cap structure and the material of the magnet are appropriately selected, so that a DC motor that can handle high temperature and high torque (DC of FIG. 1B). Motors 100E and 100F).
Even in this case, the cost can be reduced by using the standard end cap structure for both DC motors compliant with EMC standards and non-EMC.

100 ... DC motor with brush, 100A to 100F ... DC motor with brush 11 ... Flux ring,
12 ... Motor case, 121 ... Collar, 123 ... One end side of the motor case, 124 ... Boss part,
DESCRIPTION OF SYMBOLS 13 ... Bearing, 131 ... Ball bearing, 132 ... Sleeve bear, 133 ... Sleeve bear, 134 ... Sleeve bear, 135 ... Ball bearing,
14 ... Magnet, 141 ... Dry magnet, 142 ... Wet magnet, 143 ... Magnet holder,
15 ... rotor, 151 ... rotor without skew, 1511 ... shaft, 1512 ... commutator, 152 ... rotor with skew, 1520 ... rotor,
16 ... Standard end cap structure, 161 ... End cap (integral type), 1610 ... End cap body, 1611 ... Hole, 1612 ... Boss part, 1613 ... Surface of end cap body, 1614 ... Brush holder holding part, 1615 ... Brush Presser spring holding part, 1616 (1616-1, 1616-2, 1616-3, 1616-4) ... terminal / terminal slit, 1617 ... choke coil holding groove, 1618 ... condenser holder, 1619 ... resistance holding part, 1620 ... Spring retainer, 1625 ... Communication hole, 1626 ... Notch, 1627 ... Groove part for resistance connection, 1628 ... Groove part for capacitor connection, 1631 ... Claw receiving part, 1632 ... Claw receiving part, 1633 ... Slit part, 1635 ... End The outer edge of the cap body,
17 ... Brush terminal structure, 170A ... Power supply terminal, 170B ... Relay terminal, 171-1 ... Terminal terminal, 171-2 ... Terminal terminal, 1715 ... Insertion part, 172 ... Brush holder, 173 ... Pigtail, 174 ... Brush, 175 ... Brush presser spring, 176 (176-1, 176-2) ... connection terminal, 177 ... fixed claw part, 178 ... stepped part, 179 (179-1, 179-2) ... connection terminal,
DESCRIPTION OF SYMBOLS 18 ... Shield cap, 1810 ... Shield cap main body, 1801 ... Notch part, 1802 ... Notch part, 1812 ... Positioning part, 1813 ... Hole, 1814 ... Claw for bearing holding, 1815 ... Bearing holding part, 1816 ... Positioning part ,
DESCRIPTION OF SYMBOLS 19 ... Noise prevention circuit corresponding to EMC standards, 191 ... Choke coil, 192 ... Choke coil, 193 ... First capacitor (common mode), 194 ... Resistance, 195a ... Wiring, 195b ... Wiring, 196a ... Wiring, 196b ... Wiring, 197: second capacitor (normal mode), 198: wiring, 199 ... second capacitor holding unit,
P1 ... connection terminal, P2 ... connection terminal, P3 ... terminal, P4 ... terminal, P5-P12 ... connection terminal.

Claims (12)

A magnet disposed on the inner peripheral side of the motor case, a rotor having an armature winding and a commutator, a pair of brushes slidably contacting the commutator, and an end fixed to one end of the motor case and holding the brush In a DC motor with a cap,
The end cap is
The end cap body,
A pair of brush holder holding portions that are provided at opposite positions on the surface side of the end cap body and hold the pair of brushes;
First to fourth terminals and terminal slits, which are respectively provided near the outer edge of the end cap body and penetrate from the front side to the back side of the end cap body,
A first choke coil holding groove and a second choke coil holding groove provided between the pair of brushes on the surface side of the end cap body,
The first and second terminal / terminal slits are in a position sandwiching the first choke coil holding groove, and the third and fourth terminal / terminal slits are in a position sandwiching the second choke coil holding groove. Yes,
A DC motor with a brush, wherein the first to fourth terminals and the terminal slit have the same planar shape. 2. The brushed DC motor according to claim 1, wherein each of the first to fourth terminals and the terminal slit includes a slit portion and a claw receiving portion extending in a radial direction from both sides of the slit. . The end cap main body includes at least one capacitor holding portion and at least one resistance holding portion on the surface of the end cap main body and radially outward from the choke coil holding grooves. The brushed DC motor according to claim 1. A power supply terminal and a relay terminal corresponding to each terminal / terminal slit,
The power terminal includes a connection terminal, a stepped portion, a fixed claw portion, and a terminal terminal.
The relay terminal has a connection terminal, a step portion, a fixing claw portion, and an insertion portion,
The terminal portion of the power terminal and the insertion portion of the relay terminal have the same cross-sectional shape that can be inserted into the slit portion of the terminal / terminal slit,
3. The DC motor with brush according to claim 2, wherein the fixed claw portion of the power terminal and the fixed claw portion of the relay terminal have the same cross-sectional shape that can be inserted into the claw receiving portion. . The end cap is
It is composed of the end cap body and shield cap,
2. The brushed DC motor according to claim 1, wherein the shield cap has a bearing holding portion corresponding to a boss portion provided in a central portion of the end cap body. A first brush and a second brush constituting the pair of brushes;
A first relay terminal and a first power terminal corresponding to the first brush; a second relay terminal and a second power terminal corresponding to the second brush;
The first brush is connected to a connection terminal of the first relay terminal;
The second brush is connected to a connection terminal of the second relay terminal;
The first relay terminal is fixed to the first terminal / terminal slit,
The second relay terminal is fixed to the third terminal / terminal slit,
The connection terminal of the first power supply terminal is connected to the second terminal / terminal slit,
6. The brushed DC motor according to claim 5, wherein a connection terminal of the second power supply terminal is connected to the fourth terminal / terminal slit. Comprising a first brush and a second brush constituting the pair of brushes;
The first brush is connected to a connection terminal of a first power supply terminal;
The second brush is connected to a connection terminal of a second power supply terminal;
The first power terminal is fixed to the first terminal / terminal slit,
6. The brushed DC motor according to claim 5, wherein the second power terminal is fixed to the third terminal / terminal slit. A second condenser holding part is provided on the back surface of the end cap body, and the second condenser is fixed to the second condenser holding part,
The end cap body has a communication hole,
The brushed DC motor according to claim 6, wherein the second capacitor and the pair of power supply terminal connection terminals are connected by wiring through the communication hole. A method of manufacturing a brushed DC motor,
The DC motor with brush includes a magnet disposed on an inner peripheral side of a motor case, a rotor having an armature winding and a commutator, first and second brushes slidably in contact with the commutator, and the motor case And an end cap that is fixed to one end of the brush and holds the brushes.
The motor case, the magnet, the rotor, the first and second brushes, and the end cap are all common to a DC motor with a noise countermeasure circuit and a DC motor without the noise countermeasure circuit. Configuration,
The end cap has a pair of brush holder holding portions, a choke coil holding groove, a resistance connecting groove, and a capacitor connecting groove on the surface side of the end cap main body, each near the outer edge of the end cap main body. A step of preparing a standard end cap structure having first to fourth terminals and terminal slits penetrating from the front surface side to the back surface side of the end cap body;
Fixing the relay terminal to the first and third terminal / terminal slits by sandwiching the relay terminal from both sides of the end cap body;
Fixing the power terminal to the second and fourth terminals / terminal slits by sandwiching the power terminal from both sides of the end cap body;
Holding each of the first and second brushes on the brush holder holding portion;
Connecting the first and second brushes to the power terminal via the relay terminal, and connecting the anti-noise circuit between the relay terminal and the power terminal,
The first and second terminal / terminal slits are at positions sandwiching the first choke coil holding groove, and the third and fourth terminal / terminal slits are at positions sandwiching the second choke coil holding groove. A method for manufacturing a brushed DC motor, wherein: The power supply terminal and the relay terminal each have a step portion and a fixed claw portion,
The stepped portion is applied to the surface of the end cap body, and the fixing claw portion is pressed from the back side of the end cap body, so that the power terminal and the relay terminal are sandwiched between both ends of the end cap body. The method for manufacturing a brushed DC motor according to claim 9, wherein the method is fixed to a cap body. The standard end cap structure has a groove portion for resistance connection and a groove portion for capacitor connection on the surface side of the end cap main body and radially outside the choke coil holding groove.
On the surface side of the end cap body, between each of the connection terminals of the relay terminal and the power supply terminal, respectively, a choke coil is connected,
Connect one end of a resistor and a capacitor to a terminal on the power supply terminal side of the choke coil,
The method of manufacturing a DC motor with a brush according to claim 10, wherein the other end of the resistor and the capacitor is connected to the motor case. The standard end cap structure has a second condenser holding portion on the back side of the end cap body, and has a communication hole that communicates between the front surface and the back surface of the end cap body.
Fixing the second condenser to the second condenser holding portion;
11. The DC motor with brush according to claim 10, wherein the power terminal and the relay terminal on the surface side of the end cap body and the second capacitor are connected by a conductor through the communication hole. Method.

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