EP0036444A2 - Method of manufacturing commutators by cold-shaping - Google Patents

Method of manufacturing commutators by cold-shaping Download PDF

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Publication number
EP0036444A2
EP0036444A2 EP80107080A EP80107080A EP0036444A2 EP 0036444 A2 EP0036444 A2 EP 0036444A2 EP 80107080 A EP80107080 A EP 80107080A EP 80107080 A EP80107080 A EP 80107080A EP 0036444 A2 EP0036444 A2 EP 0036444A2
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EP
European Patent Office
Prior art keywords
grooves
longitudinal
longitudinal grooves
groove
shrinking
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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.)
Granted
Application number
EP80107080A
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German (de)
French (fr)
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EP0036444B1 (en
EP0036444A3 (en
Inventor
Joze Potocnik
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KOLEKTOR PO
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KOLEKTOR PO
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Priority to AT80107080T priority Critical patent/ATE10315T1/en
Publication of EP0036444A2 publication Critical patent/EP0036444A2/en
Publication of EP0036444A3 publication Critical patent/EP0036444A3/en
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Publication of EP0036444B1 publication Critical patent/EP0036444B1/en
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06Manufacture of commutators
    • H01R43/08Manufacture of commutators in which segments are not separated until after assembly
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49009Dynamoelectric machine
    • Y10T29/49011Commutator or slip ring assembly
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49799Providing transitory integral holding or handling portion

Definitions

  • the invention relates to a method for producing press commutators, in which longitudinal grooves are worked into the inner circumferential surface of a hollow cylindrical copper body in an arrangement corresponding to the lamella division, the width of which is measured in the circumferential direction being reduced by a subsequent radial shrinkage of the copper body.
  • Methods of this type are predominantly used in the production of press commutators with a large copper usable height and solid solder ring, as are required, for example, for automotive starter motors.
  • the invention is therefore based on the object to provide a method for the production of press commutators which is also suitable for blanks with a solder ring and which allows close tolerances with respect to the division of the commutator and the insulation width between the fins to be maintained without difficulty, even if the commutator is one has a large usable copper height.
  • a longitudinal groove is worked into the outer circumferential surface of each future lamella, which is separated from one another by the internal longitudinal grooves, with a depth which results in an at least approximately the same radial distance of its groove base from the longitudinal axis of the copper body as it did the bottom of the groove of the internal longitudinal grooves has this longitudinal axis, and a circumferential offset with respect to the adjacent internal longitudinal groove, which results in a ridge breaking between the two longitudinal grooves during the subsequent shrinking, and a width which is equal to the reduction in the subsequent shrinkage Width of each internal longitudinal groove.
  • the extent of the reduction in the width of the inner longitudinal grooves can be determined by the groove width of the outer longitudinal grooves with narrow tolerances, which also avoids division errors and also the final width of the inner longitudinal grooves, which corresponds to the width of the insulation of the finished commutator, can be maintained with tight tolerances.
  • the blank produced by the method according to the invention can be further processed in a known manner.
  • NEN split after the shrinking on the lamellae holding members and after pressing with the insulating molding compound the lamellae are separated from each other by turning off the commutator according to the depth of the original outer longitudinal grooves.
  • the copper body can also be produced in a known manner.
  • rings which have been formed by rolling a band can also be used.
  • the internal longitudinal grooves are preferably arranged so that the joint lies radially outside one of these longitudinal grooves.
  • each of the parts of the material closing the outer longitudinal grooves are firmly connected by friction welding to the lamella having this longitudinal groove.
  • a connection of these material parts with the associated lamellae has the advantage that the blank does not have to be held together by a barrel ring until it is inserted into the tool for pressing out with the insulating molding compound.
  • longitudinal grooves 3 are worked into the inner surface by means of a star-shaped stamp in the extrusion process, all of which are parallel to and parallel to one another Longitudinal axis of the copper body 1 lie and are arranged according to the desired division of the commutator to be manufactured.
  • the depth of the longitudinal grooves 3 is chosen so that the distance of their groove base 3 'from the outer surface of the copper body 1 is equal to the thickness of the layer to be twisted off after pressing with an insulating molding compound.
  • the groove depth thus corresponds to the radial height of the lamellae 4 formed by the longitudinal grooves 3 in the finished commutator.
  • the width of the longitudinal grooves 3 measured in the circumferential direction is greater than the width of the insulation of the finished commutator, that is to say greater than the distance of two adjacent lamellae of the finished commutator measured in the circumferential direction.
  • Radial grooves 5 are also machined into the end face of the flange 2 facing away from the cylindrical part of the copper body 1, namely in an extension of the longitudinal grooves 3. The arrangement of the radial grooves 5 therefore corresponds to the division of the commutator. As shown in Fig. 1, the depth of the radial grooves 5 is chosen so that the distance of their groove base from the other end face of the flange 2 is equal to the thickness of the layer to be turned later.
  • Longitudinal grooves 6 are worked into the outer lateral surface of the copper body 1 by means of extrusion, namely in the same number as the inner longitudinal grooves 3.
  • the depth of the outer longitudinal grooves 6 is equal to the thickness of the layer to be turned later. Therefore, the groove base of the outer grooves 6 lies in the cylindrical surface defined by the groove base 3 'of the inner longitudinal grooves 3.
  • the width of the longitudinal grooves 6 measured in the circumferential direction is equal to the extent to which the width of the internal longitudinal grooves 3 must be reduced by a later shrinking of the copper body 1.
  • the difference between the width of a longitudinal groove 3 and a longitudinal groove 6 is therefore equal to the width of the insulation of the finished commutator. How particular.
  • the outer longitudinal grooves 6 are offset in relation to the inner longitudinal grooves 3 in the circumferential direction, all in the same sense and the same extent.
  • a web 7 is present between the groove base 3 'of each longitudinal groove 3 and the groove base of the adjacent longitudinal groove 6, the width of which is measured in the circumferential direction is selected such that when the copper body 1 subsequently shrinks, it is roughly defined by the groove base 3' Cylinder surface breaks.
  • the width of the webs 7 is somewhat less than the width of the external grooves 6.
  • the copper body 1 is inserted into a shrinking tool which, as shown in FIGS. 3a, 3b and 4a, 4b, has a support star 11 which is guided longitudinally displaceably in a bushing 10.
  • the support star 11 has a number of strips 12 corresponding to the number of longitudinal grooves 3 and aligned with this in its end section which can be inserted into the copper body 1.
  • the strips 12 are, as shown in Fig. 3a, 3b, profiled so that they can engage a bit in the longitudinal grooves 3 and abut their flanks when the copper body 1 has been shrunk to the correct size.
  • the shrinking tool Concentrically around the support star 11, the shrinking tool has pressure pieces 13 arranged radially displaceably in a number corresponding to the number of strips 12. These pressure pieces, which, as shown in Fig. 4a, 4b, are profiled so that they can be applied simultaneously to the outer surface of the cylindrical part of the copper body 1 and to the outer surface of the flange 2, press each of the fins 4 in the radial direction against the Tragstern 11, as can be seen in Fig. 3b. Since the circumference of the copper body 1 is inevitably reduced during this radial movement, the webs 7 and 9 break off, as shown in FIGS. 3b and 5, in that through the groove base of the longitudinal grooves 3 and 6 or radial grooves 5 and 9 defined area.
  • the width of the longitudinal grooves 3 and the radial grooves 5 decreases to the final value, since a further reduction in the circumference and thus a further reduction in the width of the grooves 3 and 5 is no longer possible if the bridges 14 and 15 have completely filled the grooves 6 and 8 and come into contact with the remaining groove flank.
  • the copper body 1 is again a rigid body.
  • the support star 11 is now pulled out of the copper body 1, which is supported on a bushing 10 and a holding part of the shrinking tool receiving it.
  • the shrunk copper body 1 can then be stored without a barrel ring or the like until it is pressed out with an insulating molding compound.
  • anchoring hooks are formed on the inside of the slats 4 before they are pressed out by splitting, which significantly improve the connection of the slats to the molding compound.
  • the cylindrical part of the copper body pers 1 and the flange 2 turned until the bridges 14 and 15 are removed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Press Drives And Press Lines (AREA)
  • Push-Button Switches (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

A method for manufacturing commutators for electric motors wherein a hollow cylindrical body is provided having longitudinal grooves and ridges on its inner surface. The circumferential widths of the inner grooves are initially larger than the desired ultimate widths. A plurality of longitudinal outer grooves are formed on the outer surface of the cylindrical body, the outer grooves each having a bottom wall radially spaced from the longitudinal axis a distance substantially equal to the radial spacing of the bottom walls of the inner groove from the longitudinal axis. The outer grooves are staggered circumferentially relative to the inner grooves and the spaces therebetween define a plurality of yieldable cross-pieces. Radially inwardly directed shrinking forces are applied uniformly to the outer surface of the cylindrical member to break the yieldable cross-pieces and thereby decrease the widths of the inner grooves, the decrease thereof being equal to the widths of the outer grooves.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung von Preßstoffkommutatoren, bei dem in die Innenmantelfläche eines hohlzylindrischen Kupferkörpers in einer der Lamellenteilung entsprechenden Anordnung durch Kaltumformung Längsnuten eingearbeitet werden, deren in Umfangsrichtung gemessene Breite durch ein anschließendes, radiales Schrumpfen des Kupferkörpers vermindert wird.The invention relates to a method for producing press commutators, in which longitudinal grooves are worked into the inner circumferential surface of a hollow cylindrical copper body in an arrangement corresponding to the lamella division, the width of which is measured in the circumferential direction being reduced by a subsequent radial shrinkage of the copper body.

Verfahren dieser Art werden vorwiegend bei der Fertigung von Preßstoffkommutatoren mit großer Kupfernutzhöhe und massivem Lötkranz, wie sie beispielsweise für Automobilanlassermotoren benötigt werden, eingesetzt.Methods of this type are predominantly used in the production of press commutators with a large copper usable height and solid solder ring, as are required, for example, for automotive starter motors.

Da bei großer Kupfernutzhöhe die Tiefe der Nuten, welche beim fertigen Kommutator dessen Lamellen voneinander trennen, verhältnismäßig groß ist im Vergleich zu der die Breite der Isolation bestimmenden Nutbreite, und die Standzeit von Preßstempeln, mit denen derartige Nuten durch Kaltumformung eingearbeitet werden können, gering ist, ist man dazu übergegangen, die Nuten mit vergrößerter Breite in einen im Durchmesser größeren Kupferkörper einzuarbeiten und danach die Nutbreite auf den gewünschten Wert durch ein radiales Schrumpfen des Kupferkörpers zu bringen. Ein wesentlicher Nachteil dieses bekannten Verfahrens besteht aber darin, daß es nur bei Kupferkörpern ohne Lötkranz angewendet werden kann. Besonders störend ist ferner, daß, bedingt durch die Brücken zwischen dem Nutgrund der innen liegenden Längsnuten und der Außenmantelfläche, welche bei dem Schrumpfen gestaucht werden müssen, sich keine gleichmäßige Reduzierung der Breite und auch keine genaue Einhaltung der Kommutatorteilung' erreichen läßt. Letzteres ist sowohl im Hinblick auf ein eventuell notwendig werdendes Aussägen eines Teils der Isolationsschicht als auch aus elektrischen Gründen sehr nachteilig.Since the depth of the grooves, which separate the lamellas of the finished commutator, is comparatively large compared to the groove width determining the width of the insulation, and the service life of press rams, with which such grooves can be worked in by cold forming, is short, it has become common to incorporate the grooves with an enlarged width into a copper body of larger diameter and then bring the groove width to the desired value by radially shrinking the copper body. A major disadvantage of this known method, however, is that it can only be used for copper bodies without a solder ring. It is also particularly disruptive that, due to the bridges between the bottom of the inside of the longitudinal grooves and the outer surface, which have to be compressed during shrinking, no uniform reduction in width and also no exact adherence to the commutator pitch can be achieved. The latter is very disadvantageous both with regard to the need to saw out part of the insulation layer and for electrical reasons.

Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren zur Herstellung von Preßstoffkommutatoren zu schaffen, das auch für Rohlinge mit Lötkranz geeignet ist und ohne Schwierigkeiten die Einhaltung enger Toleranzen hinsichtlich der Teilung des Kommutators und der Isolationsbreite zwischen den Lamellen gestattet, auch wenn der Kommutator eine große Kupfernutzhöhe aufweist.The invention is therefore based on the object to provide a method for the production of press commutators which is also suitable for blanks with a solder ring and which allows close tolerances with respect to the division of the commutator and the insulation width between the fins to be maintained without difficulty, even if the commutator is one has a large usable copper height.

Mit einem Verfahren der eingangs genannten Art ist diese Aufgabe erfindungsgemäß dadurch gelöst, daß vor dem Schrumpfen in die Außenmantelfläche jeder durch die innen liegenden Längsnuten voneinander abgeteilten, zukünftigen Lamellen eine Längsnut eingearbeitet wird mit einer Tiefe, die einen zumindest annähernd gleichen radialen Abstand ihres Nutgrundes von der Längsachse des Kupferkörpers ergibt, wie ihn der Nutgrund der innen liegenden Längsnuten von dieser Längsachse hat, und einer Versetzung in Umfangsrichtung gegenüber der benachbarten innen liegenden Längsnut, die einen beim nachfolgenden Schrumpfen brechenden Steg zwischen diesen beiden Längsnuten ergibt, sowie einer Breite, die gleich der beim nachfolgenden Schrumpfen zu bewirkenden Verminderung der Breite jeder innen liegenden Längsnut ist. Dadurch, daß die mit Hilfe der außen liegenden Längsnuten gebildeten Stege zwischen jeder innen liegenden Längsnut und der ihr zugeordneten, benachbarten äußeren Längsnut beim Schrumpfen brechen, behindern diese Stege nicht ein gleichmäßiges Schrumpfen des Kupferkörpers, Daher wird durch den Schrumpfvorgang die Teilung nicht verändert. Ferner kann durch die Nutbreite der außen liegenden Längsnuten mit engen Toleranzen das Ausmaß der Verminderung der Breite der innen liegenden Längsnuten festgelegt werden, wodurch ebenfalls Teilungsfehler vermieden werden und außerdem die endgültige Breite der innen liegenden Längsnuten, welche der Breite der Isolation des fertigen Kommutators entspricht, mit engen Toleranzen eingehalten werden kann.With a method of the type mentioned above This object is achieved according to the invention in that, prior to shrinking, a longitudinal groove is worked into the outer circumferential surface of each future lamella, which is separated from one another by the internal longitudinal grooves, with a depth which results in an at least approximately the same radial distance of its groove base from the longitudinal axis of the copper body as it did the bottom of the groove of the internal longitudinal grooves has this longitudinal axis, and a circumferential offset with respect to the adjacent internal longitudinal groove, which results in a ridge breaking between the two longitudinal grooves during the subsequent shrinking, and a width which is equal to the reduction in the subsequent shrinkage Width of each internal longitudinal groove. Because the webs formed with the help of the outer longitudinal grooves break between each inner longitudinal groove and the associated outer longitudinal groove when shrinking, these webs do not hinder a uniform shrinking of the copper body, therefore the pitch is not changed by the shrinking process. Furthermore, the extent of the reduction in the width of the inner longitudinal grooves can be determined by the groove width of the outer longitudinal grooves with narrow tolerances, which also avoids division errors and also the final width of the inner longitudinal grooves, which corresponds to the width of the insulation of the finished commutator, can be maintained with tight tolerances.

Die Weiterverarbeitung des nach dem erfindungsgemäßen Verfahren hergestellten Rohlings kann in bekannter Weise erfolgen. Beispielsweise können nach dem Schrumpfen innen an den Lamellen Halteorgane angespalten und nach dem Auspressen mit der isolierenden Preßmasse die Lamellen dadurch voneinander getrennt werden, daß man den Kommutator entsprechend der Tiefe der ursprünglichen äußeren Längsnuten abdreht. Ebenso kann in bekannter Weise der Kupferkörper hergestellt werden. Außer in sich geschlossene Ringe oder Scheiben können auch Ringe verwendet werden, die durch Rollieren eines Bandes gebildet worden sind. Vorzugsweise werden dabei die innenliegenden Längsnuten so angeordnet, daß die Stoßstelle radial außerhalb einer dieser Längsnuten liegt.The blank produced by the method according to the invention can be further processed in a known manner. For example, NEN split after the shrinking on the lamellae holding members and after pressing with the insulating molding compound, the lamellae are separated from each other by turning off the commutator according to the depth of the original outer longitudinal grooves. The copper body can also be produced in a known manner. In addition to self-contained rings or disks, rings which have been formed by rolling a band can also be used. The internal longitudinal grooves are preferably arranged so that the joint lies radially outside one of these longitudinal grooves.

Bei einem Kupferkörper, der zur Bildung des massiven Lötkranzes einen Flansch aufweist, werden in die vom zylindrischen Teil wegweisende Stirnseite des Flansches sich an die innen liegenden Längsnuten anschließende Radialnuten und in die andereStirnseite sich an die außen liegenden Längsnuten anschließende Radialnuten eingearbeitet. Zwischen jeder inneren Längsnut und der ihr benachbarten äußeren Längsnut ist dann wie im zylindrischen Abschnitt des Kupferkörpers je ein Steg vorhanden, der beim anschließenden Schrumpfen bricht und dadurch ein gleichmäßiges Schrumpfen des Kupferkörpers nicht beeinträchtigt.In the case of a copper body which has a flange to form the solid solder ring, radial grooves adjoining the inner longitudinal grooves and facing away from the cylindrical part are worked into the radial end, and radial grooves adjoining the outer longitudinal grooves in the other end. Between each inner longitudinal groove and the adjacent outer longitudinal groove there is, as in the cylindrical section of the copper body, a web which breaks during the subsequent shrinking and thereby does not impair uniform shrinking of the copper body.

Alle Nuten können durch Fließpressen eingearbeitet werden, und zwar gleichzeitig, was aus Fertigungsgründen vorteilhaft ist.All grooves can be machined by extrusion, at the same time, which is advantageous for manufacturing reasons.

Bei einer besonders vorteilhaften Ausführungsform des erfindungsgemäßen Verfahrens wird beim Schrumpfen des Kupferkörpers und seines gegebenenfalls vorhandenen Flansches jede der eine die außen liegenden Längsnuten schließenden Werkstoffpartien durch Reibschweißen mit der diese Längsnut aufweisenden Lamelle fest verbunden. Eine Verbindung dieser Werkstoffpartien mit den zugeordneten Lamellen ergit den Vorteil, daß der Rohling nicht durch einen Faßring zusammengehalten werden muß, bis er in das Werkzeug zum Auspressen mit der isolierenden Preßmasse eingesetzt wird.In a particularly advantageous embodiment of the method according to the invention, when the Copper body and its flange, if any, each of the parts of the material closing the outer longitudinal grooves are firmly connected by friction welding to the lamella having this longitudinal groove. A connection of these material parts with the associated lamellae has the advantage that the blank does not have to be held together by a barrel ring until it is inserted into the tool for pressing out with the insulating molding compound.

Im folgenden ist die Erfindung anhand eines in der Zeichnung in verschiedenen Fertigungsstadien dargestellten Rohlings im einzelnen erläutert. Es zeigen:

  • Fig. 1 eine perspektivisch und teilweise geschnitten dargestellte Ansicht eines Rohlings nach dem Einarbeiten der Längsnuten,
  • Fig. 2 einen unvollständig und in vergrößertem Maßstab dargestellten Querschnitt durch den Rohling im Fertigungsstadium gemäß Fig. 1,
  • Fig. 3a einen unvollständig dargestellten Querschnitt und 3b durch den in ein Schrumpfwerkzeug eingesetzten Rohling , und zwar Fig. 3a vor dem Schrumpfen und Fig. 3b nach beendetem Schrumpfen des Rohlings,
  • Fig. 4a einen Längsschnitt durch den in das Schrumpfwerk-und 4b zeug eingesetzten Rohling , und zwar Fig. 4a vor dem Schrumpfen und Fig. 4b nach beendetem Schrumpfen des Rohlings,
  • Fig. 5 einen in vergrößertem Maßstab dargestellten Querschnitt durch den Rohling nach dem Schrumpfen.
The invention is explained in detail below with the aid of a blank shown in the drawing in various production stages. Show it:
  • 1 is a perspective and partially sectioned view of a blank after incorporating the longitudinal grooves,
  • 2 shows an incomplete and enlarged cross section through the blank in the manufacturing stage according to FIG. 1,
  • 3a shows an incompletely illustrated cross section and 3b through the blank inserted into a shrinking tool, specifically FIG. 3a before shrinking and FIG. 3b after shrinking of the blank has ended,
  • 4a shows a longitudinal section through the blank inserted into the shrinking tool and 4b, namely FIG. 4a before shrinking and FIG. 4b after the blank has shrunk,
  • Fig. 5 shows a cross section through the blank after shrinking, shown on an enlarged scale.

In einen hohlzylindrischen Kupferkörper 1, der an seinem einen Ende einen radial nach außen überstehenden Flansch 2 aufweist und durch Kaltumformung aus einem Ring hergestellt worden ist, werden in die Innenfläche mittels eines sternförmigen Stempels im Fließpreßverfahren Längsnuten 3 eingearbeitet, die alle parallel zueinander und parallel zur Längsachse des Kupferköpers 1 liegen sowie entsprechend der gewünschten Teilung des herzustellenden Kommutators angeordnet sind. Die Tiefe der Längsnuten 3 wird so gewählt, daß der Abstand ihres Nutgrundes 3' von der Außenmantelfläche des Kupferkörpers 1 gleich der Stärke der nach dem Auspressen mit einer isolierenden Preßmasse abzudrehenden Schicht ist. Damit entspricht die Nuttiefe der radialen Höhe der durch die Längsnuten 3 gebildeten Lamellen 4 beim fertigen Kommutator. Die in Umfangsrichtung gemessene Breite der Längsnuten 3 ist hingegen größer als die Breite der Isolation des fertigen Kommutators, also größer als der in Umfangsrichtung gemessene Abstand zweier benachbarten Lamellen des fertigen Kommutators. In die an dem zylindrischen Teil des Kupferkörpers 1 abgekehrte Stirnfläche des Flansches 2 werden ebenfalls durch Fließpressen Radialnuten 5 eingearbeitet, und zwar in Verlängerung der Längsnuten 3. Die Anordnung der Radialnuten 5 entspricht daher der Teilung des Kommutators. Wie Fig. 1 zeigt, ist auch die Tiefe der Radialnuten 5 so gewählt, daß der Abstand ihres Nutgrundes von der anderen Stirnfläche des Flansches 2 gleich der Stärke der später abzudrehenden Schicht ist.In a hollow cylindrical copper body 1, which has a radially outwardly projecting flange 2 at one end and has been produced from a ring by cold forming, longitudinal grooves 3 are worked into the inner surface by means of a star-shaped stamp in the extrusion process, all of which are parallel to and parallel to one another Longitudinal axis of the copper body 1 lie and are arranged according to the desired division of the commutator to be manufactured. The depth of the longitudinal grooves 3 is chosen so that the distance of their groove base 3 'from the outer surface of the copper body 1 is equal to the thickness of the layer to be twisted off after pressing with an insulating molding compound. The groove depth thus corresponds to the radial height of the lamellae 4 formed by the longitudinal grooves 3 in the finished commutator. In contrast, the width of the longitudinal grooves 3 measured in the circumferential direction is greater than the width of the insulation of the finished commutator, that is to say greater than the distance of two adjacent lamellae of the finished commutator measured in the circumferential direction. Radial grooves 5 are also machined into the end face of the flange 2 facing away from the cylindrical part of the copper body 1, namely in an extension of the longitudinal grooves 3. The arrangement of the radial grooves 5 therefore corresponds to the division of the commutator. As shown in Fig. 1, the depth of the radial grooves 5 is chosen so that the distance of their groove base from the other end face of the flange 2 is equal to the thickness of the layer to be turned later.

In die Außenmantelfläche des Kupferkörpers 1 werden durch Fließpressen Längsnuten 6 eingearbeitet, und zwar in gleicher Anzahl wie die innen liegenden Längsnuten 3. Die Tiefe der außen liegenden Längsnuten 6 ist gleich der Dicke der später abzudrehenden Schicht. Daher liegt der Nutgrund der außen liegenden Nuten 6 in der durch den Nutgrund 3' der innen liegenden Längsnuten 3 definierten Zylinderfläche. Die in Umfangsrichtung gemessene Breite der Längsnuten 6 ist gleich dem Maß, um das die Breite der innen liegenden Längsnuten 3 durch ein später auszuführendes Schrumpen des Kupferkörpers 1 vermindert werden muß. Die Differenz aus der Breite einer Längsnut 3 und einer Längsnut 6 ist also gleich der Breite der Isolation des fertigen Kommutators. Wie insbesonderefig. 2 zeigt, sind die außen liegenden Längsnuten 6 gegenüber den innen liegenden Längsnuten 3 in Umfangsrichtung, und zwar alle im gleichen Sinne und gleichen Ausmaß, versetzt. Dadurch ist zwischen dem Nutgrund 3' jeder Längsnut 3 und dem Nutgrund der benachbarten Längsnut 6 ein Steg 7 vorhanden, dessen in Umfangsrichtung gemessene Breite so gewählt wird, daß er bei dem später erfolgenden Schrumpfen des Kupferkörpers 1 etwa in der durch den Nutgrund 3' definierten Zylinderfläche bricht. Im Ausführungsbeispiel ist die Breite der Stege 7 etwas geringer als die Breite der außen liegenden Nuten 6.Longitudinal grooves 6 are worked into the outer lateral surface of the copper body 1 by means of extrusion, namely in the same number as the inner longitudinal grooves 3. The depth of the outer longitudinal grooves 6 is equal to the thickness of the layer to be turned later. Therefore, the groove base of the outer grooves 6 lies in the cylindrical surface defined by the groove base 3 'of the inner longitudinal grooves 3. The width of the longitudinal grooves 6 measured in the circumferential direction is equal to the extent to which the width of the internal longitudinal grooves 3 must be reduced by a later shrinking of the copper body 1. The difference between the width of a longitudinal groove 3 and a longitudinal groove 6 is therefore equal to the width of the insulation of the finished commutator. How particular. 2 shows, the outer longitudinal grooves 6 are offset in relation to the inner longitudinal grooves 3 in the circumferential direction, all in the same sense and the same extent. As a result, a web 7 is present between the groove base 3 'of each longitudinal groove 3 and the groove base of the adjacent longitudinal groove 6, the width of which is measured in the circumferential direction is selected such that when the copper body 1 subsequently shrinks, it is roughly defined by the groove base 3' Cylinder surface breaks. In the exemplary embodiment, the width of the webs 7 is somewhat less than the width of the external grooves 6.

In Verlängerung der Längsnuten 6 werden auch in die dem zylindrischen Teil des Kupferkörpers 1 zugekehrte Stirnfläche des Flansches 2 Radialnuten 8 durch Fließpressen eingearbeitet. Wie Fig. 1 erkennen läßt, ist die Tiefe dieser Radialnuten 8 gleich der Stärke der später abzudrehenden Schicht. Bedingt durch diese Nuttiefe und die Versetzung der Radialnuten 8 gegenüber den Radialnuten 5 ist auch am Flansch 2 jeder Radialnut 5 und der zugeordneten Radialnut 8 ein dünner Steg 9 vorhanden, welcher beim späteren Schrumpfen des Kupferkörpers 1 bricht.In the extension of the longitudinal grooves 6 of the K 2 are radial grooves incorporated upferkörpers 1 facing end face of the flange 8 by means of extrusion in the said cylindrical portion. As can be seen in FIG. 1, the depth of these radial grooves 8 is equal to the thickness the layer to be turned off later. Due to this groove depth and the offset of the radial grooves 8 with respect to the radial grooves 5, there is also a thin web 9 on the flange 2 of each radial groove 5 and the associated radial groove 8, which breaks when the copper body 1 is later shrunk.

Nachdem alle Nuten 3, 5, 6 und 8 eingearbeitet sind, wird der 'Kupferkörper 1 in ein Schrumpfwerkzeug eingesetzt, das, wie Fig. 3a, 3b und 4a, 4b zeigen, einen in einer Buchse 10 längsverschiebbar geführten Tragstern 11 aufweist. Der Tragstern 11 hat eine der Zahl der Längsnuten 3 entsprechende und auf diese ausgerichtete Anzahl von Leisten 12 in seinem in den Kupferkörper 1 einführbaren Endabschnitt. Die Leisten 12 sind, wie Fig. 3a, 3b zeigen, so profiliert, daß sie ein Stück weit in die Längsnuten 3 eingreifen können und dabei an deren Flanken anliegen, wenn der Kupferkörper 1 auf das richtige Maß geschrumpft worden ist. Konzentrisch um den Tragstern 11 herum weist das Schrumpfwerkzeug radial verschiebbar angeordnete Druckstücke 13 in einer der Zahl der Leisten 12 entsprechenden Anzahl auf. Diese Druckstücke, die, wie Fig. 4a, 4b zeigen, so profiliert sind, daß sie gleichzeitig an die Außenmantelfläche des zylindrischen Teils des Kupferkörpers 1 und an die Aussenmantelfläche des Flansches 2 angelegt werden können, drücken jede der Lamellen 4 in radialer Richtung gegen den Tragstern 11, wie dies Fig. 3b erkennen läßt. Da sich bei dieser Radialbewegung der Umfang des Kupferkörpers 1 zwangsläufig verkleinert, brechen die Stege 7 und 9 ab, und zwar, wie die Fig. 3b und 5 zeigen, in der durch den Nutgrund der Längsnuten 3 und 6 bzw. Radialnuten 5 und 9 definierten Fläche. Die radial außerhalb der Längsnuten 3 bzw. der Radialnuten 5 vorhandenen Brücken 14 bzw. 15 schieben sich nach dem Bruch der Stege in Umfangsrichtung in die Längsnuten 6 bzw. die Radialnuten 8 hinein, bis sie diese Nuten vollständig ausgefüllt haben. Bei dieser Relativbewegung zwischen den benachbarten Lamellen 4 vermindert sich die Breite der Längsnuten 3 und der Radialnuten 5 auf den endgültigen Wert, da eine weitere Verkleinerung des Umfanges und damit eine weitere Verminderung der Breite der Nuten 3 und 5 nicht mehr möglich ist, wenn die Brücken 14 und 15 die Nuten 6 und 8 vollständig ausgefüllt haben und an der verbliebenen Nutflanke in Anlage kommen. Infolge der radialen Belastung, unter der die Brücken 14 und 15 stehen, während sie in die Längsnuten 6 bzw. die Radialnuten 8 hineingedrückt werden, kommt es zu einer Reibverschweißung, so daß am Ende des Schrumpfvorgangs alle Lamellen 4 über die Brücken 14 und 15 fest miteinander verbunden sind, der Kupferkörper 1 also wieder ein starrer Körper ist. Der Tragstern 11 wird nun aus dem Kupferkörper 1 herausgezogen, der sich dabei auf einer Buchse 10 und einem diese aufnehmenden Halteteil des Schrumpfwerkzeuges abstützt.After all of the grooves 3, 5, 6 and 8 have been worked in, the copper body 1 is inserted into a shrinking tool which, as shown in FIGS. 3a, 3b and 4a, 4b, has a support star 11 which is guided longitudinally displaceably in a bushing 10. The support star 11 has a number of strips 12 corresponding to the number of longitudinal grooves 3 and aligned with this in its end section which can be inserted into the copper body 1. The strips 12 are, as shown in Fig. 3a, 3b, profiled so that they can engage a bit in the longitudinal grooves 3 and abut their flanks when the copper body 1 has been shrunk to the correct size. Concentrically around the support star 11, the shrinking tool has pressure pieces 13 arranged radially displaceably in a number corresponding to the number of strips 12. These pressure pieces, which, as shown in Fig. 4a, 4b, are profiled so that they can be applied simultaneously to the outer surface of the cylindrical part of the copper body 1 and to the outer surface of the flange 2, press each of the fins 4 in the radial direction against the Tragstern 11, as can be seen in Fig. 3b. Since the circumference of the copper body 1 is inevitably reduced during this radial movement, the webs 7 and 9 break off, as shown in FIGS. 3b and 5, in that through the groove base of the longitudinal grooves 3 and 6 or radial grooves 5 and 9 defined area. The bridges 14 and 15, which are present radially outside the longitudinal grooves 3 and the radial grooves 5, slide into the longitudinal grooves 6 and the radial grooves 8 in the circumferential direction after the ridges have broken until they have completely filled these grooves. With this relative movement between the adjacent slats 4, the width of the longitudinal grooves 3 and the radial grooves 5 decreases to the final value, since a further reduction in the circumference and thus a further reduction in the width of the grooves 3 and 5 is no longer possible if the bridges 14 and 15 have completely filled the grooves 6 and 8 and come into contact with the remaining groove flank. As a result of the radial load under which the bridges 14 and 15 stand while they are pressed into the longitudinal grooves 6 and the radial grooves 8, friction welding occurs, so that at the end of the shrinking process all the lamellae 4 are fixed over the bridges 14 and 15 are interconnected, the copper body 1 is again a rigid body. The support star 11 is now pulled out of the copper body 1, which is supported on a bushing 10 and a holding part of the shrinking tool receiving it.

Der geschrumpfte Kupferkörper 1 kann anschließend ohne einen Faßring oder dergleichen gelagert werden, bis er mit isolierender Preßmasse ausgepresst wird. In der Regel werden noch vor dem Auspressen von den Lamellen 4 an deren Innenseite Verankerungshaken durch Abspalten gebildet, welche die Verbindung der Lamellen mit dem Preßmassekörper wesentlich verbessern. Nach dem Auspressen wird der zylindrische Teil des Kupferkörpers 1 und der Flansch 2 so weit abgedreht, bis die Brücken 14 und 15 beseitigt sind.The shrunk copper body 1 can then be stored without a barrel ring or the like until it is pressed out with an insulating molding compound. As a rule, anchoring hooks are formed on the inside of the slats 4 before they are pressed out by splitting, which significantly improve the connection of the slats to the molding compound. After pressing, the cylindrical part of the copper body pers 1 and the flange 2 turned until the bridges 14 and 15 are removed.

Claims (4)

1. Verfahren zur Herstellung von Preßstoffkommutatoren, bei dem in die Innenmantelfläche eines hohlzylindrischen Kupferkörpers (1) in einer der Lamellenteilung entsprechenden Anordnung durch Kaltumformung Längsnuten (3) eingearbeitet werden, deren in Umfangsrichtung gemessene Breite durch ein anschließendes, radiales Schrumpfen des Kupferkörpers (1) vermindert wird, dadurch gekennzeichnet , daß vor dem Schrumpfen in die Außenmantelfläche jeder durch die innen liegenden Längsnuten (3) voneinander abgeteilten, zukünftigen Lamellen (2) eine Längsnut (6) eingearbeitet wird mit einer Tiefe, die einen zumindest annähernd gleichen radialen Abstand ihres Nutgrundes von der Längsachse des Kupferkörpers (1) ergibt, wie ihn der Nutgrund (3') der innen liegenden Nuten (3) von dieser Längsachse hat, und einer Versetzung in Umfangsrichtung gegenüber der benachbarten, innen liegenden Längsnut (3), die einen beim nachfolgenden Schrumpfen brechenden Steg (7) zwischen den beiden Längsnuten (3 und 6) ergibt, sowie einer Breite, die gleich der beim nachfolgenden Schrumpfen zu bewirkenden Verminderung der Breite jeder innen liegenden Längsnut (3) ist.1. A process for the production of press commutators, in which longitudinal grooves (3) are worked into the inner lateral surface of a hollow cylindrical copper body (1) in an arrangement corresponding to the lamella division, the width of which is measured in the circumferential direction by a subsequent radial shrinking of the copper body (1). is reduced, characterized in that, before shrinking, a longitudinal groove (6) is worked into the outer lateral surface of each future lamella (2) separated from one another by the internal longitudinal grooves (3) with a depth which is at least approximately the same radial distance from the base of its groove from the longitudinal axis of the copper body (1), as it has the groove base (3 ') of the internal grooves (3) from this longitudinal axis, and a circumferential offset in relation to the adjacent, internal longitudinal groove (3), which one in the following Shrink breaking web (7) between the two longitudinal grooves (3 and 6) erg ibt, and a width that is equal to the reduction of the width of each internal longitudinal groove (3) to be brought about in the subsequent shrinking. 2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß bei einem einen Flansch (2) aufweisenden Kupferkörper (1) in die vom zylindrischen Teil wegweisende Stirnseite des Flansches (2) sich an die innen liegenden Längsnuten (3) anschließende Radialnuten (5) und auf der anderen Stirnseite sich an die außen liegenden Längsnuten (6) anschließende Radialnuten (8) eingearbeitet werden.2. The method according to claim 1, characterized in that with a flange (2) having copper body (1) in the end face of the flange (2) pointing away from the cylindrical part to the inner longitudinal grooves (3) adjoining radial grooves (5) and on the other Radial grooves (8) adjoining the longitudinal grooves (6) on the outside are incorporated. 3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß alle Nuten (3, 6 bzw. 5, 8) vorzugsweise in einem Arbeitsgang, durch Fließpressen eingearbeitet werden.3. The method according to claim 1 or 2, characterized in that all grooves (3, 6 or 5, 8) are preferably incorporated in one operation, by extrusion. 4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß beim Schrumpfen des hohlzylindrischen Körpers (1) und seines gegebenenfalls vorhandenen Flansches (2) jede der eine die außen liegenden Längsnuten (6 bzw. 8) schliessenden Werkstoffpartien (14 bzw. 15) durch Reibschweißen mit der diese Längsnuten (6 bzw. 8) aufweisenden Lamelle (4) fest verbunden wird.4. The method according to any one of claims 1 to 3, characterized in that when shrinking the hollow cylindrical body (1) and its flange (2), if any, each of the one the outer longitudinal grooves (6 or 8) closing material parts (14 or 15) is firmly connected by friction welding to the lamella (4) having these longitudinal grooves (6 or 8).
EP80107080A 1980-03-24 1980-11-15 Method of manufacturing commutators by cold-shaping Expired EP0036444B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT80107080T ATE10315T1 (en) 1980-03-24 1980-11-15 METHOD OF MANUFACTURE OF COMPRESSION COMMUTATORS.

Applications Claiming Priority (2)

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YU817/80 1980-03-24
YU00817/80A YU81780A (en) 1980-03-24 1980-03-24 Method of producing a cast in commutator

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EP0036444A2 true EP0036444A2 (en) 1981-09-30
EP0036444A3 EP0036444A3 (en) 1981-11-11
EP0036444B1 EP0036444B1 (en) 1984-11-14

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EP (1) EP0036444B1 (en)
JP (1) JPS56133954A (en)
AT (1) ATE10315T1 (en)
BG (1) BG32120A3 (en)
DD (1) DD155126A5 (en)
DE (1) DE3069641D1 (en)
DK (1) DK147562C (en)
ES (1) ES8202198A1 (en)
HU (1) HU182241B (en)
PL (1) PL137637B1 (en)
RO (1) RO78997A (en)
SU (1) SU1041023A3 (en)
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3201027A1 (en) * 1982-01-15 1983-07-28 Robert Bosch Gmbh, 7000 Stuttgart Method for producing a commutator ring for a commutator
EP0111688A2 (en) * 1982-11-23 1984-06-27 Robert Bosch Gmbh Method of manufacturing a commutator ring for a commutator
WO2010009959A2 (en) * 2008-07-25 2010-01-28 Robert Bosch Gmbh Commutator for an electrical machine and system

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3333335A1 (en) * 1983-09-15 1985-03-28 Robert Bosch Gmbh, 7000 Stuttgart METHOD FOR PRODUCING AN INTERMEDIATE FOR A COMMUTATOR SEGMENT RING
DE102013207887A1 (en) * 2013-04-30 2014-10-30 Robert Bosch Gmbh Method for producing a collector for a commutation device
CN104874714B (en) * 2015-04-24 2016-06-01 浙江东瑞机械工业有限公司 A kind of commutator segment making method
CN104759569B (en) * 2015-04-24 2016-06-15 浙江东瑞机械工业有限公司 Commutator segment manufacture method
CN106734736A (en) * 2015-11-24 2017-05-31 宁波胜克换向器有限公司 A kind of pressing mold that commutator hook foot press system is rounded

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DE961910C (en) * 1954-12-31 1957-04-11 Bosch Gmbh Robert Method for manufacturing a commutator from a ring-shaped workpiece
DE2028857A1 (en) * 1969-06-13 1970-12-17

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Publication number Priority date Publication date Assignee Title
JPS4837761B1 (en) * 1969-06-13 1973-11-13

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Publication number Priority date Publication date Assignee Title
DE961910C (en) * 1954-12-31 1957-04-11 Bosch Gmbh Robert Method for manufacturing a commutator from a ring-shaped workpiece
DE2028857A1 (en) * 1969-06-13 1970-12-17

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3201027A1 (en) * 1982-01-15 1983-07-28 Robert Bosch Gmbh, 7000 Stuttgart Method for producing a commutator ring for a commutator
EP0111688A2 (en) * 1982-11-23 1984-06-27 Robert Bosch Gmbh Method of manufacturing a commutator ring for a commutator
EP0111688A3 (en) * 1982-11-23 1986-07-16 Robert Bosch Gmbh Method of manufacturing a commutator ring for a commutator
US4698902A (en) * 1982-11-23 1987-10-13 Robert Bosch Gmbh Method of making commutator rings
WO2010009959A2 (en) * 2008-07-25 2010-01-28 Robert Bosch Gmbh Commutator for an electrical machine and system
WO2010009959A3 (en) * 2008-07-25 2010-06-03 Robert Bosch Gmbh Commutator for an electrical machine and system

Also Published As

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SU1041023A3 (en) 1983-09-07
ES498388A0 (en) 1982-01-01
HU182241B (en) 1983-12-28
BG32120A3 (en) 1982-05-14
EP0036444B1 (en) 1984-11-14
RO78997A (en) 1982-06-25
YU81780A (en) 1982-10-31
DK147562C (en) 1985-03-04
PL137637B1 (en) 1986-07-31
DD155126A5 (en) 1982-05-12
ES8202198A1 (en) 1982-01-01
DE3069641D1 (en) 1984-12-20
DK147562B (en) 1984-10-01
PL229183A1 (en) 1981-10-30
US4370799A (en) 1983-02-01
JPS56133954A (en) 1981-10-20
EP0036444A3 (en) 1981-11-11
DK487180A (en) 1981-09-25
ATE10315T1 (en) 1984-11-15

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