EP0036444B1 - Method of manufacturing commutators by cold-shaping - Google Patents

Method of manufacturing commutators by cold-shaping Download PDF

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Publication number
EP0036444B1
EP0036444B1 EP80107080A EP80107080A EP0036444B1 EP 0036444 B1 EP0036444 B1 EP 0036444B1 EP 80107080 A EP80107080 A EP 80107080A EP 80107080 A EP80107080 A EP 80107080A EP 0036444 B1 EP0036444 B1 EP 0036444B1
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EP
European Patent Office
Prior art keywords
grooves
longitudinal
groove
longitudinal grooves
worked
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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.)
Expired
Application number
EP80107080A
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German (de)
French (fr)
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EP0036444A2 (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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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06—Manufacture of commutators
    • H01R43/08—Manufacture of commutators in which segments are not separated until after assembly
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine
    • Y10T29/49011—Commutator or slip ring assembly
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49799—Providing transitory integral holding or handling portion

Definitions

  • the invention relates to a method for producing compression-molded commutators, in which longitudinal grooves are worked into the inner lateral 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 compression of the copper body.
  • Methods of this type are known (cf. DE-C-961 910). They are mainly used in the production of compression molding commutators with a large copper usable height and solid solder ring, such as are required for automotive starter motors, for example.
  • the invention is therefore based on the object of providing a method for producing compression molded 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 lamellae to be observed without difficulty, even if the commutator has one has a large usable copper height.
  • this object is achieved according to the invention in that, prior to being pressed together, a longitudinal groove is machined into the outer lateral surface of each future lamella, which is separated from one another by the internal longitudinal grooves, with a depth that is at least approximately the same radial distance from its groove base from the longitudinal axis of the copper body results from the groove base of the internal longitudinal grooves from this longitudinal axis, and a circumferential offset in relation to the adjacent internal longitudinal groove, which results in a ridge breaking between these two longitudinal grooves during the subsequent compression, and a width that is the same is the reduction in the width of each internal longitudinal groove to be brought about in the subsequent compression.
  • the webs formed with the aid of the outer longitudinal grooves break between each inner longitudinal groove and the adjacent outer longitudinal groove assigned to them during the pressing together, these webs do not hinder a uniform pressing of the copper body. Therefore, the pitch is not changed by the pressing 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, thereby also avoiding 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.
  • holding members can be split on the inside of the lamellae and, after pressing out with the insulating molding compound, the lamellae can be separated from one another 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 strip can also be used.
  • the internal longitudinal grooves are preferably arranged in such a way that the joint lies radially outside of one of these longitudinal grooves.
  • 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 its 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, measured in the circumferential direction, of two adjacent lamellae of the finished commutator.
  • Radial grooves 5 are also worked 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 also selected 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 machined 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 amount by which the width of the inner longitudinal grooves 3 has to 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. As shown in FIG.
  • 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 with the same extent.
  • a web 7 the width of which is measured in the circumferential direction is selected such that when the copper body 1 is later pressed together, it is roughly the same as that defined by the groove base 3' Cylinder surface breaks.
  • the width of the webs 7 is somewhat less than the width of the grooves 6 lying on the outside.
  • radial grooves 8 are also worked into the end face of the flange facing the cylindrical part of the copper body 1 by extrusion molding. As can be seen in FIG. 1, the depth of these radial grooves 8 is equal to the thickness of the layer to be turned 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 pressed together.
  • the copper body 1 is inserted into a pressing tool which, as shown in FIGS. 3a, 3b and 4a, 4b, has a support star 11 which is guided in a sleeve 10 so as to be longitudinally displaceable.
  • 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 FIGS. 3a, 3b, profiled in such a way that they can engage a little in the longitudinal grooves 3 and thereby rest on their flanks when the copper body 1 has been pressed together to the correct dimension.
  • the pressing tool Concentrically around the support star 11, the pressing 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 Support star 11, as can be seen in FIG. 3b. Since the radial movement of the order catch of the copper body 1 inevitably reduced, the webs 7 and 9 break off, as shown in FIGS. 3b and 5, in the area defined by the bottom of the longitudinal grooves 3 and 6 or radial grooves 5 and 9.
  • 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 when 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 pressing tool which receives it.
  • the compressed 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 lamellae 4 before they are pressed out, by splitting off, which significantly improve the connection of the lamellae to the molding compound body.
  • the cylindrical part of the copper body 1 and the flange 2 are turned off until the bridges 14 and 15 are removed.

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  • 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)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Press Drives And Press Lines (AREA)
  • Push-Button Switches (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 Formpresskommutatoren, 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 Zusammenpressen des Kupferkörpers vermindert wird.The invention relates to a method for producing compression-molded commutators, in which longitudinal grooves are worked into the inner lateral 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 compression of the copper body.

Verfahren dieser Art sind bekannt (vgl. DE-C-961 910). Sie werden vorwiegend bei der Fertigung von Formpresskommutatoren mit grosser Kupfernutzhöhe und massivem Lötkranz, wie sie beispielsweise für Automobilanlassermotoren benötigt werden, eingesetzt.Methods of this type are known (cf. DE-C-961 910). They are mainly used in the production of compression molding commutators with a large copper usable height and solid solder ring, such as are required for automotive starter motors, for example.

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 Zusammenpressen 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 Zusammenpressen 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 from one another, is relatively large in comparison with the groove width determining the width of the insulation, and the service life of press dies, with which such grooves can be worked in by cold forming, is short , one has started to incorporate the grooves with an enlarged width into a copper body with a larger diameter and then to bring the groove width to the desired value by radially compressing 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 outside surface, which have to be compressed when pressed together, there is no uniform reduction in the width and also no exact adherence to the commutator division. 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 Formpresskommutatoren 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 of providing a method for producing compression molded 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 lamellae to be observed without difficulty, even if the commutator has one has a large usable copper height.

Mit einem Verfahren der eingangs genannten Art ist diese Aufgabe erfindungsgemäss dadurch gelöst, dass vor dem Zusammenpressen 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 Zusammenpressen brechenden Steg zwischen diesen beiden Längsnuten ergibt, sowie einer Breite, die gleich der beim nachfolgenden Zusammenpressen zu bewirkenden Verminderung der Breite jeder innen liegenden Längsnut ist.With a method of the type mentioned at the outset, this object is achieved according to the invention in that, prior to being pressed together, a longitudinal groove is machined into the outer lateral surface of each future lamella, which is separated from one another by the internal longitudinal grooves, with a depth that is at least approximately the same radial distance from its groove base from the longitudinal axis of the copper body results from the groove base of the internal longitudinal grooves from this longitudinal axis, and a circumferential offset in relation to the adjacent internal longitudinal groove, which results in a ridge breaking between these two longitudinal grooves during the subsequent compression, and a width that is the same is the reduction in the width of each internal longitudinal groove to be brought about in the subsequent compression.

Dadurch, dass die mit Hilfe der aussen liegenden Längsnuten gebildeten Stege zwischen jeder innen liegenden Längsnut und der ihr zugeordneten, benachbarten äusseren Längsnut beim Zusammenpressen brechen, behindern diese Stege nicht ein gleichmässiges Zusammenpressen des Kupferkörpers. Daher wird durch den Pressvorgang 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.The fact that the webs formed with the aid of the outer longitudinal grooves break between each inner longitudinal groove and the adjacent outer longitudinal groove assigned to them during the pressing together, these webs do not hinder a uniform pressing of the copper body. Therefore, the pitch is not changed by the pressing 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, thereby also avoiding 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 Zusammenpressen 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 geschlossenen Ringen 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, after pressing together, holding members can be split on the inside of the lamellae and, after pressing out with the insulating molding compound, the lamellae can be separated from one another 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 strip can also be used. The internal longitudinal grooves are preferably arranged in such a way that the joint lies radially outside of 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 Radiatnuten und in die andere Stirnseite 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 Zusammenpressen bricht und dadurch ein gleichmässiges Zusammenpressen des Kupferkörpers nicht beeinträchtigt.In the case of a copper body which has a flange to form the solid solder ring, the radial grooves adjoining the longitudinal grooves on the inside of the cylindrical part and the radial grooves adjoining the longitudinal grooves on the outside are worked into the other end face. Between each inner longitudinal groove and the adjacent outer longitudinal groove, as in the cylindrical section of the copper body, there is a web which breaks during the subsequent compression and does not impair uniform pressing 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 Zusammenpressen 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 ergibt 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. 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 und 3b einen unvollständig dargestellten Querschnitt durch den in ein Presswerkzeug eingesetzten Rohling, und zwar Fig. 3a vor dem Zusammenpressen und Fig. 3b nach dem Zusammenpressen des Rohlings,
  • Fig. 4a und 4b einen Längsschnitt durch den in das Presswerkzeug eingesetzten Rohling, und zwar Fig. 4a vor dem Zusammenpressen und
  • Fig. 4b nach dem Zusammenpressen des Rohlings,
  • Fig. 5 einen in vergrössertem Massstab dargestellten Querschnitt durch den Rohling nach dem Zusammenpressen.
In a particularly advantageous embodiment of the method according to the invention, when the copper body and its flange, if any, are pressed together, each of the material parts closing the longitudinal grooves on the outside is friction-welded to the longitudinal groove Slat firmly connected. A connection of these material parts with the assigned lamellae results in 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. 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 and 3b an incomplete cross-section through the blank inserted into a pressing tool, namely Fig. 3a before pressing together and Fig. 3b after pressing the blank together,
  • 4a and 4b show a longitudinal section through the blank inserted into the pressing tool, namely Fig. 4a before pressing and
  • 4b after pressing the blank together,
  • 5 shows a cross section through the blank after being pressed together 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 Kupferkörpers 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 its 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, on the other hand, is greater than the width of the insulation of the finished commutator, that is to say greater than the distance, measured in the circumferential direction, of two adjacent lamellae of the finished commutator. Radial grooves 5 are also worked 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 also selected 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 Schrumpfen 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 insbesondere Fig. 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 Zusammenpressen 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 machined 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 amount by which the width of the inner longitudinal grooves 3 has to 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. As shown in FIG. 2 in 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 with the same extent. As a result, between the groove base 3 'of each longitudinal groove 3 and the groove base of the adjacent longitudinal groove 6, there is a web 7, the width of which is measured in the circumferential direction is selected such that when the copper body 1 is later pressed together, it is roughly the same as that 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 grooves 6 lying on the outside.

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 Zusammenpressen des Kupferkörpers 1 bricht.In an extension of the longitudinal grooves 6, 2 radial grooves 8 are also worked into the end face of the flange facing the cylindrical part of the copper body 1 by extrusion molding. As can be seen in FIG. 1, the depth of these radial grooves 8 is equal to the thickness of the layer to be turned 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 pressed together.

Nachdem alle Nuten 3, 5, 6 und 8 eingearbeitet sind, wird der Kupferkörper 1 in ein Presswerkzeug 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 zusammengepresst worden ist. Konzentrisch um den Tragstern 11 herum weist das Presswerkzeug 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 Pressvorgangs alle Lamellen 4 über die Brükken 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 Presswerkzeuges abstützt.After all the grooves 3, 5, 6 and 8 have been worked in, the copper body 1 is inserted into a pressing tool which, as shown in FIGS. 3a, 3b and 4a, 4b, has a support star 11 which is guided in a sleeve 10 so as to be longitudinally displaceable. 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 FIGS. 3a, 3b, profiled in such a way that they can engage a little in the longitudinal grooves 3 and thereby rest on their flanks when the copper body 1 has been pressed together to the correct dimension. Concentrically around the support star 11, the pressing 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 Support star 11, as can be seen in FIG. 3b. Since the radial movement of the order catch of the copper body 1 inevitably reduced, the webs 7 and 9 break off, as shown in FIGS. 3b and 5, in the area defined by the bottom of the longitudinal grooves 3 and 6 or radial grooves 5 and 9. 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 when 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, there is a frictional welding, so that at the end of the pressing 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 pressing tool which receives it.

Der zusammengepresste 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 compressed 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 lamellae 4 before they are pressed out, by splitting off, which significantly improve the connection of the lamellae to the molding compound body. After pressing, the cylindrical part of the copper body 1 and the flange 2 are turned off until the bridges 14 and 15 are removed.

Claims (5)

1. A method for producing molded commutators, in which longitudinal grooves (3) are worked by cold forming into the inner surface area of a hollow cylindrical body (1) in an arrangement corresponding to the segment pitch, the width of the longitudinal grooves (3) measured in the peripheral direction being reduced by subsequent radial compression of the copper body (1), characterized in that before compression a longitudinal groove (6) is worked into the outer surface area of each future segment (2) separated from the others by the inside longitudinal grooves (3), each groove (6) having a depth resulting in an at least approximately equal radial distance between the base of the groove (6) and the longitudinal axis of the copper body (1), the same distance as between the bases (3') of the inside grooves (3) and this longitudinal axis, each groove (6) further being staggered in the peripheral direction relative to the adjacent inside longitudinal groove (3), thus forming a bridge (7) between the two longitudinal grooves (3 and 6) which breaks during the subsequent compression, and each groove (6) finally having a width equal to the reduction in width of each inside longitudinal groove (3) as comes about during the subsequent compression.
2. A method as in claim 1, characterized in that, in a copper body (1) having a flange (2), radial grooves (5) joining up with the inside longitudinal grooves (3) are worked into the face of the flange (2) pointing away from the cylindrical portion, and radial grooves (8) joining up with the outside longitudinal grooves (6) are worked in on the other face.
3. A method as in claim 1 or 2, characterized in that all grooves (3, 6 and 5, 8) are worked in by extrusion, preferably in one operation.
4. A method as in any of claims 1 to 3, characterized in that, during the compression of the hollow cylindrical body (1) and the flange (2) possibly present on it, each of the sections of material (14 and 15) closing an outside longitudinal groove (6 and 8) is firmly connected by friction welding to the segment (4) bearing these longitudinal grooves (6 and 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)

Application Number Priority Date Filing Date Title
YU00817/80A YU81780A (en) 1980-03-24 1980-03-24 Method of producing a cast in commutator
YU817/80 1980-03-24

Publications (3)

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

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EP80107080A Expired EP0036444B1 (en) 1980-03-24 1980-11-15 Method of manufacturing commutators by cold-shaping

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US (1) US4370799A (en)
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)
YU (1) YU81780A (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3201027C2 (en) * 1982-01-15 1986-11-27 Robert Bosch Gmbh, 7000 Stuttgart Method for manufacturing a commutator ring
DE3243191A1 (en) * 1982-11-23 1984-05-24 Robert Bosch Gmbh, 7000 Stuttgart METHOD FOR PRODUCING A COMMUTATOR RING FOR A COMMUTATOR
DE3333335A1 (en) * 1983-09-15 1985-03-28 Robert Bosch Gmbh, 7000 Stuttgart METHOD FOR PRODUCING AN INTERMEDIATE FOR A COMMUTATOR SEGMENT RING
DE102008040717A1 (en) * 2008-07-25 2010-01-28 Robert Bosch Gmbh Commutator for an electric machine as well as system
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

Family Cites Families (3)

* Cited by examiner, † Cited by third party
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
JPS4837761B1 (en) * 1969-06-13 1973-11-13
DE2028857C3 (en) * 1969-06-13 1975-05-28 Hitachi Ltd., Tokio

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HU182241B (en) 1983-12-28
PL229183A1 (en) 1981-10-30
SU1041023A3 (en) 1983-09-07
RO78997A (en) 1982-06-25
PL137637B1 (en) 1986-07-31
DK147562B (en) 1984-10-01
DK487180A (en) 1981-09-25
ES498388A0 (en) 1982-01-01
YU81780A (en) 1982-10-31
JPS56133954A (en) 1981-10-20
DE3069641D1 (en) 1984-12-20
US4370799A (en) 1983-02-01
BG32120A3 (en) 1982-05-14
EP0036444A2 (en) 1981-09-30
DD155126A5 (en) 1982-05-12
ATE10315T1 (en) 1984-11-15
ES8202198A1 (en) 1982-01-01
DK147562C (en) 1985-03-04
EP0036444A3 (en) 1981-11-11

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