GB2238669A - Sprayed commutators and winding connections thereto - Google Patents
Sprayed commutators and winding connections thereto Download PDFInfo
- Publication number
- GB2238669A GB2238669A GB8924580A GB8924580A GB2238669A GB 2238669 A GB2238669 A GB 2238669A GB 8924580 A GB8924580 A GB 8924580A GB 8924580 A GB8924580 A GB 8924580A GB 2238669 A GB2238669 A GB 2238669A
- Authority
- GB
- United Kingdom
- Prior art keywords
- commutator
- segments
- copper
- conductors
- sprayed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000004804 winding Methods 0.000 title description 5
- 239000000463 material Substances 0.000 claims abstract description 5
- 239000002184 metal Substances 0.000 claims abstract description 3
- 229910052751 metal Inorganic materials 0.000 claims abstract description 3
- 238000005507 spraying Methods 0.000 claims abstract description 3
- 238000000034 method Methods 0.000 claims description 19
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 18
- 229910052802 copper Inorganic materials 0.000 claims description 18
- 239000010949 copper Substances 0.000 claims description 18
- 239000004020 conductor Substances 0.000 claims description 15
- 239000011810 insulating material Substances 0.000 claims description 3
- 238000007493 shaping process Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 238000010276 construction Methods 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- YXLXNENXOJSQEI-UHFFFAOYSA-L Oxine-copper Chemical compound [Cu+2].C1=CN=C2C([O-])=CC=CC2=C1.C1=CN=C2C([O-])=CC=CC2=C1 YXLXNENXOJSQEI-UHFFFAOYSA-L 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R39/00—Rotary current collectors, distributors or interrupters
- H01R39/02—Details for dynamo electric machines
- H01R39/04—Commutators
- H01R39/06—Commutators other than with external cylindrical contact surface, e.g. flat commutators
Landscapes
- Motor Or Generator Current Collectors (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Conductive segments of a commutator of an electrical machine are made by spraying metal on to an insulating base to provide the material for the segments.
Description
COMMUTATORS FOR ELECTRICAL MACHINES
This invention relates to commutators for electrical machines.
In known types of electrical machine the armature windings are fastened into preformed copper segments of a commutator, usually by means of brazing or welding. As is well known, the segments provide a smooth surface for electrical contact with brushes which convey electrical current to or from the armature windings of the machine.
The copper commutators required for such electrical machines are expensive to produce, not only because each one requires a large amount of copper which is a costly raw material, but also because the shaping of each commutator segment involves a complicated drawing process. Moreover, fitting of the armature windings into the commutator during construction of the machine is a slow process which usually has to be performed manually in order to obtain the necessary accuracy.
According to one aspect of the invention the segments of a commutator of an electrical machine are made by spraying copper or other metal onto an insulating base. Such a technique avoids the use of preformed commutator segments and so provides a cheaper and/or quicker method of manufacture of the commutator.
A particular aspect of the invention is the simplification of attachment of the ends of the armature windings to respective armature segments. According to this aspect of the invention there is provided a process for fitting ends of armature conductors to a commutator wherein the commutator comprises a base of insulating material, and wherein in a first stage the conductors are fitted through channels in the base, and in a second stage the ends of the conductors are sprayed with copper to provide the material for the commutator segments and simultaneously to effect the connection between the conductors and the segments.
The invention will now be described by way of example with reference to the accompanying drawings, in which:
Figures 1A and IB show a first stage in the process according to the invention;
Figures 2A and 2B show a second stage; and
Figures 3A and 3B show a final stage in the process according to the invention.
The following description and the drawings all describe the process of the invention with reference to face-plate type commutators for use with brushes which bear in an axial direction on the commutator segments. It is however to be understood that with only minor adaptation the method could also be applied to the more conventional barrel commutators with brushes that bear radially on commutator segments.
Figure 1A shows a partial sectional view of an electric machine. Armature laminations 1 are wound with armature conductors 2. These armature conductors may be round wire, rectangular or stranded. In a first stage of the method according to the invention, free ends 3 of the armature conductors pass through slots or holes 4 in an insulating plate 5 which forms the base shape for the commutator. The commutator rotates on motor axis 6, and the insulating plate is therefore preferably disc-shaped with a substantially circular periphery.
Figure lB shows an end view of a small section of the insulating plate viewed from point X during the first stage of the process.
Figure 2A illustrates a second stage in the construction of the commutator contacts. The ends 3 of the armature conductors are first trimmed, if necessary, so that they do not protrude much beyond the face 7 of the insulating plate.
A coating of copper 8 is then sprayed onto the face of the insulating plate in a layer which completely covers the face of the plate in the region of the conductors, as shown in
Figure 2B. The copper is spray-coated on to the face of the plate to a depth sufficient to cover the ends of the conductors and to allow the surface of the copper to be machined in the final stage of the process.
The final stage is shown in Figures 3A and 3B. The sprayed copper coating is machined to size and the rough edges at top and bottom of the spray-coated area are squared off.
The copper layer is then separated into wedge-shaped commutator segments 9, as shown in Figure 3B, by cutting slots 10 in the copper layer between each group of conductors.
The face-plate commutator is now ready for use. The brushes are able to form electrical contact with the smooth copper surface 11 of the commutator, as in any conventional solid copper commutator, although a substantial proportion of the commutator is made of an insulating material, such as a rigid plastic which is much cheaper and more easily formed into the required shape, than copper.
It will also be apparent that the copper swarf which is produced by the machining in the final stage of the process may be collected and recycled for future use. The process is therefore very economical in its use of copper in comparison to ordinary methods of construction of commutators.
Claims (6)
1. A method of making the conductive segments of a commutator of an electrical machine, comprising spraying metal onto an insulating base to provide the material for the segments.
2. A method according to claim 1 further comprising shaping the surface of the material.
3. A process for fitting ends of armature conductors to a commutator, wherein in a first stage the conductors are fitted through channels in a base, and in a second stage the ends of the conductors are sprayed with copper to provide the material for commutator segments and simultaneously to effect the connection between the conductors and the segments.
4. A process according to claim 3 wherein a third stage comprises shaping the copper to form the commutator segments.
5. A process according to claim 3 or claim 4 wherein the base comprises a disc of insulating material.
6. An electrical commutator comprising a segmented layer of sprayed copper on an insulating former.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8924580A GB2238669A (en) | 1989-11-01 | 1989-11-01 | Sprayed commutators and winding connections thereto |
| PCT/GB1990/001668 WO1991006992A1 (en) | 1989-11-01 | 1990-10-31 | Commutators for electrical machines |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8924580A GB2238669A (en) | 1989-11-01 | 1989-11-01 | Sprayed commutators and winding connections thereto |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB8924580D0 GB8924580D0 (en) | 1989-12-20 |
| GB2238669A true GB2238669A (en) | 1991-06-05 |
Family
ID=10665514
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8924580A Withdrawn GB2238669A (en) | 1989-11-01 | 1989-11-01 | Sprayed commutators and winding connections thereto |
Country Status (2)
| Country | Link |
|---|---|
| GB (1) | GB2238669A (en) |
| WO (1) | WO1991006992A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2753849B1 (en) * | 1996-09-26 | 1998-10-23 | Valeo Equip Electr Moteur | ROTATING ELECTRIC MACHINE ARMATURE AND MOTOR VEHICLE STARTER COMPRISING SUCH AN ARMATURE |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB942670A (en) * | 1959-05-25 | 1963-11-27 | Electronique & Automatisme Sa | Improvements in electrical rotating machine armatures |
| GB1193014A (en) * | 1967-04-03 | 1970-05-28 | Photocircuits Corp | Aluminum Armature and Method for Making Same |
| GB2056788A (en) * | 1979-06-25 | 1981-03-18 | Portescap | Direct current micromotor |
| GB2125635A (en) * | 1982-08-10 | 1984-03-07 | Papst Motoren Gmbh & Co Kg | Direct current machine |
| WO1988006356A1 (en) * | 1987-02-12 | 1988-08-25 | Mitsubishi Denki Kabushiki Kaisha | Dc motor and manufacturing method therefor |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE2655249A1 (en) * | 1976-12-07 | 1978-06-08 | Bosch Siemens Hausgeraete | DISC COLLECTOR FOR THE COMMUTATOR OF ELECTRIC MACHINERY, IN PARTICULAR SMALL MOTORS FOR ELECTRIC HOUSEHOLD APPLIANCES |
-
1989
- 1989-11-01 GB GB8924580A patent/GB2238669A/en not_active Withdrawn
-
1990
- 1990-10-31 WO PCT/GB1990/001668 patent/WO1991006992A1/en not_active Ceased
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB942670A (en) * | 1959-05-25 | 1963-11-27 | Electronique & Automatisme Sa | Improvements in electrical rotating machine armatures |
| GB1193014A (en) * | 1967-04-03 | 1970-05-28 | Photocircuits Corp | Aluminum Armature and Method for Making Same |
| GB2056788A (en) * | 1979-06-25 | 1981-03-18 | Portescap | Direct current micromotor |
| GB2125635A (en) * | 1982-08-10 | 1984-03-07 | Papst Motoren Gmbh & Co Kg | Direct current machine |
| WO1988006356A1 (en) * | 1987-02-12 | 1988-08-25 | Mitsubishi Denki Kabushiki Kaisha | Dc motor and manufacturing method therefor |
Also Published As
| Publication number | Publication date |
|---|---|
| WO1991006992A1 (en) | 1991-05-16 |
| GB8924580D0 (en) | 1989-12-20 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US5003212A (en) | Molded commutator with a layer of insulation on the base | |
| US5006765A (en) | DC motor with coreless coil installation | |
| WO1999057797A8 (en) | Carbon commutator | |
| KR100367274B1 (en) | Stator bonding nib | |
| US3861027A (en) | Method of manufacturing a rotor assembly for a dynamo electric machine | |
| US6161275A (en) | Method of manufacturing commutators for electric motors | |
| KR100375394B1 (en) | Method for forming rotating electrical machine for rotating electrical machine and rotating electrical machine | |
| US3568309A (en) | Method of manufacturing dynamo electric machines | |
| US3648360A (en) | Method for making an aluminum armature | |
| US4490637A (en) | Electrical machine with multi disc commutator | |
| JPH06209545A (en) | Rotor shaft with slot for lead wire and color support formation by cold heading processing | |
| GB1598288A (en) | Electrical hand machine tools | |
| GB2238669A (en) | Sprayed commutators and winding connections thereto | |
| US3726003A (en) | Method of making a disk tape commutator | |
| EP0325353A2 (en) | A commutator | |
| EP0994554B1 (en) | Commutator and method of manufacturing the same | |
| US2915658A (en) | Commutators for dynamo-electric machines | |
| US1831534A (en) | Commutator assembling process | |
| US4890026A (en) | Electric motor with commutator directly molded on motor shaft and method of construction | |
| US5107160A (en) | Electrical commutator with reinforced connectors | |
| KR100401649B1 (en) | the manufacturing method of a commutator | |
| US5933939A (en) | Process for producing a commutator of a rotating machine | |
| JP3360093B2 (en) | Manufacturing method of ultra-small diameter assembled commutator | |
| GB2042813A (en) | Manufacture of combined armature and commutator | |
| KR20010110780A (en) | End shield for a commutator machine and a method for producing such an end shield |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |