EP0546317A2 - Method for manufacturing a moulded flat commutator - Google Patents

Method for manufacturing a moulded flat commutator Download PDF

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Publication number
EP0546317A2
EP0546317A2 EP92118864A EP92118864A EP0546317A2 EP 0546317 A2 EP0546317 A2 EP 0546317A2 EP 92118864 A EP92118864 A EP 92118864A EP 92118864 A EP92118864 A EP 92118864A EP 0546317 A2 EP0546317 A2 EP 0546317A2
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EP
European Patent Office
Prior art keywords
grooves
blank
jacket
segments
ring flange
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP92118864A
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German (de)
French (fr)
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EP0546317A3 (en
EP0546317B1 (en
Inventor
Joze Potocnik
Boris Kogej
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Kolektor doo
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Kolektor doo
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Publication of EP0546317A2 publication Critical patent/EP0546317A2/en
Publication of EP0546317A3 publication Critical patent/EP0546317A3/en
Application granted granted Critical
Publication of EP0546317B1 publication Critical patent/EP0546317B1/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
    • 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
    • Y10T29/49002—Electrical device making
    • Y10T29/49105—Switch making
    • 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
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/49218—Contact or terminal manufacturing by assembling plural parts with deforming
    • 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
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/4922—Contact or terminal manufacturing by assembling plural parts with molding of insulation
    • 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
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/49222—Contact or terminal manufacturing by assembling plural parts forming array of contacts or terminals

Definitions

  • the invention relates to a method for producing a pressed material commutator, which has the features of the preamble of claim 1.
  • the invention is therefore based on the object of specifying a method of the type mentioned at the outset which enables more economical production without impairing the quality of the commutator. This object is achieved by a method having the features of claim 1.
  • the blank is preferably produced by extrusion, since then, with this reshaping, the flat part can be provided on its inside with radial grooves which are aligned with the grooves and merge into them. These radial grooves, along which the separating cuts are made to divide the segments in the plan part, reduce the required depth of these separating cuts, which not only reduces the effort for separating, but also makes a significant contribution to not endangering the secure anchoring of the segments in the pressed material.
  • the shaping by extrusion also enables the simultaneous formation of a ring of inner anchoring elements according to claim 3 without additional effort.
  • the inner anchoring elements are expediently separated from one another by the grooves extending to the edge of the central bore.
  • the grooves and preferably also the grooves are advantageously given a shape which widens in a wedge shape towards the free edge of the jacket. On the one hand, such a shape is favorable for reasons of forming technology. On the other hand, it is not difficult with such a shape of the grooves to seal them when the molding compound is introduced later.
  • a circular blank is used as the starting material. This can be punched out of sheet metal or tape. However, the material consumption is lower if the round blank is formed from a disc cut from a bar material.
  • the inner anchoring elements are advantageously bent radially outward to increase their effectiveness. This bending process can be carried out in one operation by splitting off external anchoring elements from the inside of the jacket.
  • an annular disk is cut from a rod material. If the rod material is a thick-walled tube, then the disk forms a round blank 1. On the other hand, if the disk is cut off from a solid material, a central hole 2 is then punched out to form the round blank 1. In the exemplary embodiment, the round blank has 1 with an outside diameter of just over 20 mm, a thickness of 4 mm. Subsequently, the pot-shaped blank 3 shown in FIGS. 2 and 3 is formed by extrusion, which forms an annular plan part 4 and an adjoining tubular jacket 5.
  • grooves 6 are formed on the inside of the jacket 5 in the axial direction and open towards the center, the number of which corresponds to the number of segments 7 of the commutator.
  • the grooves 6 are therefore evenly distributed over the circumference of the jacket 5.
  • the width of the grooves decreases evenly from the free end face of the casing 5 towards the flat part 4.
  • the angle enclosed by the groove flanks is approximately 15 ° in the exemplary embodiment.
  • the grooves 6 are closed radially outwards by a material section 8 each.
  • the plan part 4 is also provided on its inside with radially extending grooves 9, one of which is aligned with each groove 6 and, as shown in particular in FIG.
  • the width of the grooves 9 therefore corresponds to the width of the grooves 6 at their end on the face part side. Since the segments 7 are separated from one another by separating cuts running along the grooves 9, the required depth of cut is considerably reduced by the grooves 9, to less than 2 mm in the exemplary embodiment. Since the groove 9 extends as far as the edge of the central hole 2, the groove 9 divides a collar formed on the inside of the plan part during the shaping process and delimits the central hole 2 into a number of identically designed anchoring elements 10 corresponding to the number of segments 7.
  • a radially outwardly projecting ring flange 11 is molded onto the free end of the jacket 5 of the blank 3.
  • the material parts 8 are removed, as a result of which the segments 7 are separated from one another in the region of the jacket.
  • a material layer the thickness of which is equal to or only slightly larger than the thickness of the material parts 8, is displaced in the axial direction towards the free end of the jacket 5, where in a tool receiving the blank 3 there is an annular space corresponding to the annular flange 11 to be formed, into which the displaced material flows.
  • the radial thickness of the material parts 8 is therefore chosen so that the volume of the displaced material layer is sufficient to form the ring flange 11.
  • the ring flange 11 can then be calibrated if necessary. This calibration can be carried out by means of the same press with which the extrusion of the round blank 1 and the formation of the ring flange 11 and the segmentation of the jacket 5 are carried out.
  • the connecting elements to be formed from the annular flange 11, which are arranged centrally with respect to the segments 7, are now punched out.
  • outer anchoring elements 13 are also split off on the inside of the jacket 5 from the flange side.
  • the inner anchoring elements 10 are bent radially outwards to improve their anchoring effect.
  • the blank is filled with molding material 15, leaving a central hub bore 14 free.
  • the shape that receives the blank 3 is provided with ribs that penetrate slightly from the outside into the grooves 6 and close them tightly.
  • the required contact pressure of the flanks of the ribs against the flanks of the grooves 6 can be achieved without problems thanks to the wedge-like tapering of the grooves 6 against the flat part 4.
  • the depth of penetration of the ribs is shown in Fig. 12.
  • the flat part 4 is finally segmented by cuts running along the grooves 9 and penetrating from the brush running surface 4 '.
  • the slots formed by these cuts which, as shown in FIG. 10, also penetrate somewhat into the molding material 15, are designated by 16.
  • the connection elements 12 are bent toward the brush tread 4 '.
  • the hub bore 14 is also unscrewed and the sprue of the hub body formed by the molding material 15 is removed by lowering.
  • the brush tread 4 ' can be turned.

Abstract

In the case of a method for manufacturing a moulded flat commutator having parts of the segments located in a cylindrical surface and in the case of which a pot-shaped blank having an outer ring flange and having a number of axially running grooves (which are open radially inwards and are arranged distributed uniformly over the circumference) corresponding to the number of segments is formed in the cylindrical part of the blank from material in the form of a board, on the outside of the cylindrical jacket of the blank, a coating having a thickness which corresponds at least to the radial thickness of the material elements which close the grooves radially on the outside is displaced from the outside of the flat part, corresponding to the surface on which the brushes will subsequently run, towards the free end of the jacket, forming the ring flange and opening the grooves. <IMAGE>

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Preßstoff-Plankommutators, das die Merkmale des Oberbegriffs des Anspruches 1 aufweist.The invention relates to a method for producing a pressed material commutator, which has the features of the preamble of claim 1.

Ein bekanntes Verfahren dieser Art (US 3 812 576) ist vor allem wegen seiner relativ großen Anzahl einzelner Arbeitsgänge nachteilig, die Übergänge zwischen mehreren Maschinen erforderlich machen. Außerdem kann es bei diesem Verfahren zu einer Beeinträchtigung des sicheren Verbundes zwischen den Segmenten und der Preßmasse kommen.A known method of this type (US Pat. No. 3,812,576) is disadvantageous primarily because of its relatively large number of individual operations which require transitions between several machines. In addition, this method can impair the secure bond between the segments and the molding compound.

Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren der eingangs genannten Art anzugeben, das ohne eine Beeinträchtigung der Qualität des Kommutators eine wirtschaftlichere Fertigung ermöglicht. Diese Aufgabe löst ein Verfahren mit den Merkmalen des Anspruches 1.The invention is therefore based on the object of specifying a method of the type mentioned at the outset which enables more economical production without impairing the quality of the commutator. This object is achieved by a method having the features of claim 1.

Die Trennung der Segmente im Bereich des Mantels des Rohlinges bei der Anformung des Ringflansches vereinfacht das Herstellungsverfahren wesentlich, da zum einen ein separater Arbeitsgang zum Trennen der Segmente im Bereich des Mantels entfällt und zum anderen diese Trennung vorgenommen werden kann, ehe in den Rohling der Preßstoff eingebracht wird. Das Trennen der Segmente im Bereich des Mantels kann deshalb sich nicht negativ auf die sichere Verbindung der Segmente mit der Preßmasse auswirken.The separation of the segments in the area of the blank during the shaping of the ring flange considerably simplifies the manufacturing process, since on the one hand there is no separate operation for separating the segments in the area of the jacket and on the other hand this separation can be carried out before the pressed material is in the blank is introduced. The separation of the segments in the area of the jacket can therefore not have a negative effect on the secure connection of the segments with the molding compound.

Vorzugsweise wird der Rohling durch Fließpressen hergestellt, da dann problemlos bei dieser Umformung der Planteil auf seiner Innenseite mit radialen Rillen versehen werden kann, die auf die Nuten ausgerichtet sind und in diese übergehen. Diese radialen Rillen, längs deren die Trennschnitte zur Teilung der Segmente im Planteil geführt werden, reduzieren die erforderliche Tiefe dieser Trennschnitte, was nicht nur den Aufwand für das Trennen reduziert, sondern wesentlich dazu beiträgt, die sichere Verankerung der Segmente im Preßstoff nicht zu gefährden.The blank is preferably produced by extrusion, since then, with this reshaping, the flat part can be provided on its inside with radial grooves which are aligned with the grooves and merge into them. These radial grooves, along which the separating cuts are made to divide the segments in the plan part, reduce the required depth of these separating cuts, which not only reduces the effort for separating, but also makes a significant contribution to not endangering the secure anchoring of the segments in the pressed material.

Das Umformen durch Fließpressen ermöglicht ferner die gleichzeitige Anformung eines Kranzes von inneren Verankerungselementen gemäß Anspruch 3 ohne zusätzlichen Aufwand. Dabei werden zweckmäßigerweise die inneren Verankerungselemente durch die bis zum Rand der zentralen Bohrung verlaufenden Rillen voneinander getrennt.The shaping by extrusion also enables the simultaneous formation of a ring of inner anchoring elements according to claim 3 without additional effort. The inner anchoring elements are expediently separated from one another by the grooves extending to the edge of the central bore.

Den Nuten und vorzugsweise auch den Rillen gibt man vorteilhafterweise eine sich gegen den freien Rand des Mantels hin keilförmig erweiternde Form. Zum einen ist eine solche Form aus umformungstechnischen Gründen günstig. Zum anderen ist es bei einer solchen Form der Nuten nicht schwierig, diese beim späteren Einbringen der Preßmasse abzudichten.The grooves and preferably also the grooves are advantageously given a shape which widens in a wedge shape towards the free edge of the jacket. On the one hand, such a shape is favorable for reasons of forming technology. On the other hand, it is not difficult with such a shape of the grooves to seal them when the molding compound is introduced later.

Bei einer bevorzugten Ausführungsform wird als Ausgangsmaterial eine Ronde verwendet. Diese kann aus einem Blech oder Band ausgestanzt werden. Einen geringeren Materialverbrauch hat man allerdings dann, wenn man die Ronde aus einer von einem Stangenmaterial abgeschnittenen Scheibe bildet.In a preferred embodiment, a circular blank is used as the starting material. This can be punched out of sheet metal or tape. However, the material consumption is lower if the round blank is formed from a disc cut from a bar material.

Vorteilhafterweise werden die inneren Verankerungselemente zur Erhöhung ihrer Wirksamkeit radial nach außen umgebogen. Dieser Biegevorgang kann in einem Arbeitsgang mit dem Abspalten von äußeren Verankerungelementen von der Innenseite des Mantels erfolgen.The inner anchoring elements are advantageously bent radially outward to increase their effectiveness. This bending process can be carried out in one operation by splitting off external anchoring elements from the inside of the jacket.

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

  • Fig. 1 einen Querschnitt einer Ronde,
  • Fig. 2 einen Querschnitt des aus der Ronde hergestellten Formlings,
  • Fig. 3 einen Schnitt nach der Linie 111-111 der Fig. 2,
  • Fig. 4 eine Draufsicht auf die Rückseite des Rohling nach dem Anformen des Ringflansches,
  • Fig. 5 einen Schnitt nach der Linie V-V der Fig. 4,
  • Fig. 6 eine Draufsicht auf die Rückseite des Rohlings nach dem Freistanzen der Anschlußelemente und dem Formen der Verankerungselemente,
  • Fig. 7 einen Schnitt nach der Linie VII-VII der Fig. 6,
  • Fig. 8 einen unvollständig und vergrößert dargestellten Schnitt durch den Planteil mit einer Draufsicht auf die Innenfläche des Mantels nach der Anformung des Flanschringes,
  • Fig. 9 einen Schnitt und eine Ansicht entsprechend Fig. 8 nach dem Freistanzen der Anschlußelemente,
  • Fig. 10 eine perspektivisch dargestellte Ansicht des Ausführungsbeispiels im fertigen Zustand,
  • Fig. 11 einen Schnitt nach der Linie XI-XI der Fig. 10 des Ausführungsbeispiels vor dem Biegen der Anschlußelemente,
  • Fig. 12 einen unvollständig dargestellten Schnitt nach der Linie XII-XII der Fig. 11.
The invention is explained in detail below using an exemplary embodiment shown in the drawing. Show it:
  • 1 shows a cross section of a round blank,
  • 2 shows a cross section of the blank produced from the blank,
  • 3 shows a section along the line 111-111 of FIG. 2,
  • 4 is a plan view of the back of the blank after the ring flange has been formed,
  • 5 shows a section along the line VV of FIG. 4,
  • 6 is a plan view of the back of the blank after the connection elements have been punched free and the anchoring elements have been shaped,
  • 7 shows a section along the line VII-VII of FIG. 6,
  • 8 shows an incomplete and enlarged section through the plan part with a plan view of the inner surface of the jacket after the flange ring has been formed,
  • 9 shows a section and a view corresponding to FIG. 8 after the connection elements have been punched free,
  • 10 is a perspective view of the embodiment in the finished state,
  • 11 is a section along the line XI-XI of FIG. 10 of the embodiment before bending the connection elements,
  • 12 shows an incomplete section along the line XII-XII of FIG. 11th

Zur Herstellung des in der Zeichnung dargestellten Ausführungsbeispiels eines erfindungsgemäßen Preßstoff-Plankommutators wird von einem Stangenmaterial eine Ringscheibe abgeschnitten. Handelt es sich bei dem Stangenmaterial um ein dickwandiges Rohr, dann bildet die Scheibe eine Ronde 1. Wird hingegen die Scheibe von einem Vollmaterial abgeschnitten, dann wird anschließend zur Bildung der Ronde 1 ein zentrales Loch 2 ausgestanzt. Im Ausführungsbeispiel hat die Ronde 1 bei einem Außendurchmesser von etwas mehr als 20 mm eine Dicke von 4 mm. Anschließend wird durch Fließpressen der in den Fig. 2 und 3 dargestellte topfförmige Rohling 3 gebildet, der einen kreisringförmigen Planteil 4 und einen sich daran anschließenden, rohrförmigen Mantel 5 bildet. Bei der Umformung der Ronde 1 werden an der Innenseite des Mantels 5 in diesen in axialer Richtung verlaufende und zum Zentrum hin offene Nuten 6 eingeformt, deren Anzahl der Zahl der Segmente 7 des Kommutators entspricht. Die Nuten 6 sind deshalb gleichmäßig über den Umfang des Mantels 5 verteilt. Wie insbesondere die Fig. 8 und 9 zeigen, nimmt die Breite der Nuten von der freien Stirnseite des Mantels 5 aus gegen den Planteil 4 hin gleichmäßig ab. Der von den Nutflanken eingeschlossene Winkel beträgt im Ausführungsbeispiel etwa 15°. Radial nach außen sind die Nuten 6 nach ihrer Bildung durch je eine Materialpartie 8 geschlossen. Bei der Umformung der Ronde 1 wird außerdem der Planteil 4 auf seiner Innenseite mit radial verlaufenden Rillen 9 versehen, von denen je eine auf jede Nut 6 ausgerichtet ist und, wie insbesondere Fig. 3 zeigt, in diese übergeht. Die Breite der Rillen 9 entspricht deshalb der Breite der Nuten 6 an deren planteilseitigem Ende. Da die Segmente 7 durch längs der Rillen 9 verlaufende Trennschnitte voneinander getrennt werden, wird durch die Rillen 9 die erforderliche Schnittiefe erheblich reduziert, im Ausführungsbeispiel auf weniger als 2 mm. Da sich die Rille 9 bis zum Rand des zentralen Loches 2 erstrecken, wird durch die Rille 9 ein beim Umformen innen an den Planteil angeformter, das zentrale Loch 2 berandender Bund in eine der Zahl der Segmente 7 entsprechende Anzahl von gleich ausgebildeten Verankerungselementen 10 unterteilt.To produce the exemplary embodiment of a pressed material commutator according to the invention shown in the drawing, an annular disk is cut from a rod material. If the rod material is a thick-walled tube, then the disk forms a round blank 1. On the other hand, if the disk is cut off from a solid material, a central hole 2 is then punched out to form the round blank 1. In the exemplary embodiment, the round blank has 1 with an outside diameter of just over 20 mm, a thickness of 4 mm. Subsequently, the pot-shaped blank 3 shown in FIGS. 2 and 3 is formed by extrusion, which forms an annular plan part 4 and an adjoining tubular jacket 5. When the round blank 1 is formed, grooves 6 are formed on the inside of the jacket 5 in the axial direction and open towards the center, the number of which corresponds to the number of segments 7 of the commutator. The grooves 6 are therefore evenly distributed over the circumference of the jacket 5. As shown in FIGS. 8 and 9 in particular, the width of the grooves decreases evenly from the free end face of the casing 5 towards the flat part 4. The angle enclosed by the groove flanks is approximately 15 ° in the exemplary embodiment. After their formation, the grooves 6 are closed radially outwards by a material section 8 each. When the blank 1 is formed, the plan part 4 is also provided on its inside with radially extending grooves 9, one of which is aligned with each groove 6 and, as shown in particular in FIG. 3, merges into it. The width of the grooves 9 therefore corresponds to the width of the grooves 6 at their end on the face part side. Since the segments 7 are separated from one another by separating cuts running along the grooves 9, the required depth of cut is considerably reduced by the grooves 9, to less than 2 mm in the exemplary embodiment. Since the groove 9 extends as far as the edge of the central hole 2, the groove 9 divides a collar formed on the inside of the plan part during the shaping process and delimits the central hole 2 into a number of identically designed anchoring elements 10 corresponding to the number of segments 7.

Im nächsten Arbeitsgang wird an das freie Ende des Mantels 5 des Rohlinges 3 ein radial nach außen abstehender Ringflansch 11 angeformt. Gleichzeitig werden die Materialpartien 8 entfernt, wodurch die Segmente 7 im Bereich des Mantels voneinander getrennt werden. Mittels eines Werkzeuges in Form einer zylindrischen Buchse wird, an der äußeren Stirnfläche des Planteiles 4 beginnend, eine Materialschicht, deren Dicke gleich der Dicke der Materialpartien 8 oder nur unwesentlich größer ist, in axialer Richtung gegen das freie Ende des Mantels 5 hin verdrängt, wo in einem den Rohling 3 aufnehmenden Werkzeug ein dem zu bildenden Ringflansch 11 entsprechender Ringraum vorhanden ist, in den hinein das verdrängte Material fließt. Die radiale Dicke der Materialpartien 8 ist deshalb so gewählt, daß das Volumen der verdrängten Materialschicht zur Bildung des Ringflansches 11 ausreicht.In the next step, a radially outwardly projecting ring flange 11 is molded onto the free end of the jacket 5 of the blank 3. At the same time, the material parts 8 are removed, as a result of which the segments 7 are separated from one another in the region of the jacket. By means of a tool in the form of a cylindrical bushing, starting at the outer end face of the plan part 4, a material layer, the thickness of which is equal to or only slightly larger than the thickness of the material parts 8, is displaced in the axial direction towards the free end of the jacket 5, where in a tool receiving the blank 3 there is an annular space corresponding to the annular flange 11 to be formed, into which the displaced material flows. The radial thickness of the material parts 8 is therefore chosen so that the volume of the displaced material layer is sufficient to form the ring flange 11.

Anschließend kann der Ringflansch 11, falls erforderlich, kalibriert werden. Diese Kalibrierung kann mittels derselben Presse erfolgen, mit der das Fließpressen der Ronde 1 und das Bilden des Ringflansches 11 sowie das Segmentieren des Mantels 5 durchgeführt wird.The ring flange 11 can then be calibrated if necessary. This calibration can be carried out by means of the same press with which the extrusion of the round blank 1 and the formation of the ring flange 11 and the segmentation of the jacket 5 are carried out.

In einem weiteren Arbeitsgang, der mittels einer Presse durchgeführt werden kann, deren Preßkraft wesentlich kleiner ist als diejenige, die beim Fließpressen benutzt wird, werden nun die aus dem Ringflansch 11 zu bildenden, mittig bezüglich der Segmente 7 angeordneten Anschlußelemente freigestanzt. Bei diesem Stanzvorgang werden außerdem an der Innenseite des Mantels 5 von der Flanschseite her äußere Verankerungselemente 13 abgespalten. Ferner werden die inneren Verankerungselemente 10 zur Verbesserung ihrer Verankerungswirkung radial nach außen gebogen. In dem folgenden Verfahrensschritt wird der Rohling unter Freilassung einer zentralen Nabenbohrung 14 mit Preßstoff 15 gefüllt. Die Form, die dabei den Rohling 3 aufnimmt, ist mit Rippen versehen, die geringfügig von außen her in die Nuten 6 eindringen und diese dicht verschließen. Der hierfür erforderliche Anpreßdruck der Flanken der Rippen an die Flanken der Nuten 6 läßt sich dank der keilartigen Verjüngung der Nuten 6 gegen den Planteil 4 hin problemlos erreichen. Die Eindringtiefe der Rippen ist in Fig. 12 dargestellt. Nach dem Aushärten des Preßstoffes 15 wird zum Schluß der Planteil 4 durch längs der Rillen 9 verlaufende, von der Bürstenlauffläche 4' her eindringende Schnitte segmentiert. Die durch diese Schnitte gebildeten Schlitze, die, wie Fig. 10 zeigt, auch noch etwas in den Preßstoff 15 eindringen, sind mit 16 bezeichnet. Außerdem werden noch die Anschlußelemente 12 zur Bürstenlauffläche 4' hin abgebogen. Sofern erforderlich, wird ferner die Nabenbohrung 14 ausgedreht und der Anguß des vom Preßstoff 15 gebildeten Nabenkörpers durch Senken entfernt. Schließlich kann natürlich, falls erforderlich, die Bürstenlauffläche 4' überdreht werden.In a further operation, which can be carried out by means of a press, the pressing force of which is considerably smaller than that which is used in the extrusion, the connecting elements to be formed from the annular flange 11, which are arranged centrally with respect to the segments 7, are now punched out. During this punching process, outer anchoring elements 13 are also split off on the inside of the jacket 5 from the flange side. Furthermore, the inner anchoring elements 10 are bent radially outwards to improve their anchoring effect. In the following process step, the blank is filled with molding material 15, leaving a central hub bore 14 free. The shape that receives the blank 3 is provided with ribs that penetrate slightly from the outside into the grooves 6 and close them tightly. The required contact pressure of the flanks of the ribs against the flanks of the grooves 6 can be achieved without problems thanks to the wedge-like tapering of the grooves 6 against the flat part 4. The depth of penetration of the ribs is shown in Fig. 12. After the molding material 15 has hardened, the flat part 4 is finally segmented by cuts running along the grooves 9 and penetrating from the brush running surface 4 '. The slots formed by these cuts, which, as shown in FIG. 10, also penetrate somewhat into the molding material 15, are designated by 16. In addition, the connection elements 12 are bent toward the brush tread 4 '. If necessary, the hub bore 14 is also unscrewed and the sprue of the hub body formed by the molding material 15 is removed by lowering. Finally, of course, if necessary, the brush tread 4 'can be turned.

Alle in der vorstehenden Beschreibung erwähnten sowie auch die nur allein aus der Zeichnung entnehmbaren Merkmale sind als weitere Ausgestaltungen Bestandteile der Erfindung, auch wenn sie nicht besonders hervorgehoben und insbesondere nicht in den Ansprüchen erwähnt sind.All of the features mentioned in the above description and also the features that can only be inferred from the drawing are further refinements of the invention, even if they are not particularly emphasized and in particular are not mentioned in the claims.

Claims (8)

1. Verfahren zur Herstellung eines Preßstoff-Plankommutators mit Anschlußelementen an den freien Enden der in einer Zylinderfläche liegenden Teile der Segmente, bei dem a) aus einem plattenförmigen Material durch Umformung ein topfförmiger Rohling mit einem äußeren Ringflansch und mit einer der Zahl der Segmente entsprechenden Anzahl von axial verlaufenden, radial nach innen offenen sowie gleichmäßig über den Umfang verteilt angeordneten Nuten im zylindrischen Teil des Rohling gebildet wird, b) der Innenraum des Rohlings unter Freilassung einer zentralen Bohrung mit Preßstoff gefüllt wird, c) der Ringflansch bis auf die für die Anschlußelemente benötigten Teile entfernt wird und d) der Rohling durch Einarbeiten von radial verlaufenden Schlitzen in den Planteil und Entfernen des die Nuten radial nach außen verschließenden Materials in die Segmente geteilt wird,
dadurch gekennzeichnet, daß an der Außenseite des zylindrischen Mantels (5) des Rohlinges (3) eine Schicht mit einer Dicke, welche mindestens der radialen Dicke der die Nuten (6) radial nach außen verschließenden Materialpartien (8) entspricht, von der der späteren Bürstenlauffläche (4') entsprechenden Außenseite des Planteiles (4) aus gegen das freie Ende des Mantels (5) hin unter Bildung des Ringflansches (11) und Öffnung der Nuten (6) verdrängt wird.1. A method for producing a pressed material commutator with connecting elements at the free ends of the parts of the segments lying in a cylindrical surface, in which a) from a plate-shaped material by forming a pot-shaped blank with an outer ring flange and with a number of segments corresponding to the number of axially extending, radially inward open and evenly distributed grooves are formed in the cylindrical part of the blank, b) the interior of the blank is filled with molding material, leaving a central hole free, c) the ring flange is removed except for the parts required for the connection elements and d) the blank is divided into the segments by incorporating radially extending slots into the flat part and removing the material closing the grooves radially outward,
characterized in that on the outside of the cylindrical casing (5) of the blank (3) a layer with a thickness which corresponds at least to the radial thickness of the material portions (8) closing the grooves (6) radially outwards, from that of the later brush running surface (4 ') corresponding outside of the plan part (4) is displaced towards the free end of the jacket (5) to form the ring flange (11) and opening of the grooves (6). 2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Rohling (3) durch Fließpressen hergestellt wird und daß bei dieser Umformung der Planteil (4) auf seiner Innenseite mit radialen Rillen (9) versehen wird, die auf die Nuten (6) ausgerichtet sind und in diese übergehen.2. The method according to claim 1, characterized in that the blank (3) is produced by extrusion and that in this deformation the plan part (4) is provided on its inside with radial grooves (9) which are aligned with the grooves (6) are and pass into them. 3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß bei der durch das Fließpressen bewirkten Umformung in der das zentrale Loch (2) berandenden Ringzone ein Kranz von inneren Verankerungselementen (10) gebildet wird, die in axialer Richtung von der Innenseite des Planteiles (4) abstehen und durch die in den Planteil (4) eingeformten Rillen (9) voneinander getrennt sind.3. The method according to claim 2, characterized in that a ring of inner anchoring elements (10) is formed in the deformation caused by the extrusion in the ring zone bordering the central hole (2), which in the axial direction from the inside of the plan part (4th ) protrude and are separated from one another by the grooves (9) formed in the plan part (4). 4. Verfahren nach Anspruch 2 oder 3, dadurch gekennzeichnet, daß den Nuten (6) und vorzugsweise auch den Rillen (9) eine sich vom Planteil (4) gegen den freien Rand des Mantels (5) hin keilförmig erweiternde Form gegeben wird.4. The method according to claim 2 or 3, characterized in that the grooves (6) and preferably also the grooves (9) from the flat part (4) against the free edge of the jacket (5) is given a wedge-shaped shape. 5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß als Ausgangsmaterial eine Ronde (1) verwendet wird.5. The method according to any one of claims 1 to 4, characterized in that a blank (1) is used as the starting material. 6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß die Ronde (1) aus einer von einem Stangenmaterial abgeschnittenen Scheibe gebildet wird.6. The method according to claim 5, characterized in that the blank (1) is formed from a disc cut from a rod material. 7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß die inneren Verankerungselemente (10) radial nach außen gebogen und bei diesem Verfahrensschritt von der Innenseite des Mantels (5) äußere Verankerungselemente (13) abgespalten werden.7. The method according to any one of claims 1 to 6, characterized in that the inner anchoring elements (10) are bent radially outwards and in this process step from the inside of the jacket (5) outer anchoring elements (13) are split off. 8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß in der Gießform, in die der Rohling (3) für das Füllen mit Preßstoff (15) eingebracht wird, mittels Dichtungsrippen, welche in die Nuten (6) eingreifen und an deren Flanken dicht anliegen, der Austritt von Preßstoff (15) aus den Nuten (6) verhindert wird.8. The method according to any one of claims 1 to 7, characterized in that in the casting mold, into which the blank (3) for filling with molding material (15) is introduced, by means of sealing ribs which engage in the grooves (6) and on whose flanks are tight, the escape of molding material (15) from the grooves (6) is prevented.
EP92118864A 1991-12-09 1992-11-04 Method for manufacturing a moulded flat commutator Expired - Lifetime EP0546317B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4140475 1991-12-09
DE4140475A DE4140475C2 (en) 1991-12-09 1991-12-09 Process for the production of a press commutator

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EP0546317A2 true EP0546317A2 (en) 1993-06-16
EP0546317A3 EP0546317A3 (en) 1993-12-08
EP0546317B1 EP0546317B1 (en) 1995-02-15

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EP (1) EP0546317B1 (en)
DE (2) DE4140475C2 (en)

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US5602438A (en) * 1991-02-28 1997-02-11 Robert Bosch Gmbh Roll commutator for electric motors and dynamos, and method of manufacturing it
US5970607A (en) * 1993-09-30 1999-10-26 Illinois Tool Works Inc. Method of making an electrical subassembly
JP2823037B2 (en) * 1993-11-11 1998-11-11 矢崎総業株式会社 Wire holding case
GB2286487A (en) * 1994-02-12 1995-08-16 Johnson Electric Sa Planar moulded carbon segment commutator
DE19514795C1 (en) * 1995-04-21 1996-06-05 Anton Holzhauer Umformtechnik Method of manufacturing a commutator
KR100278006B1 (en) * 1998-11-11 2001-01-15 윤종용 Microwave oven with commutator, and manufacturing method of commutator for microwave
DE19925286A1 (en) 1999-06-02 2000-12-07 Kolektor D O O Method for producing a flat commutator and a flat commutator produced by this method
US6849170B2 (en) * 2003-01-27 2005-02-01 Institut National D'optique Process for making microdevice with movable microplatform
DE102005028789A1 (en) * 2005-06-16 2006-12-28 Kautt & Bux Gmbh Plan commutator for use in e.g. fuel pump, has carrier body with slots arranged in reference to commutator segments such that separating tool does not come in contact with contact surface of body during segmentation

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FR2548471A1 (en) * 1983-06-28 1985-01-04 Paris & Du Rhone PERFECTIONAL FRONT COLLECTOR

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GB738823A (en) * 1952-06-24 1955-10-19 Hoover Ltd Improvements relating to commutators
US3812576A (en) * 1971-10-25 1974-05-28 Nippon Denso Co Method of making commutator for revolving armature
FR2548471A1 (en) * 1983-06-28 1985-01-04 Paris & Du Rhone PERFECTIONAL FRONT COLLECTOR

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WO2008040654A1 (en) * 2006-09-29 2008-04-10 Robert Bosch Gmbh Flat commutator

Also Published As

Publication number Publication date
DE4140475A1 (en) 1993-06-17
EP0546317A3 (en) 1993-12-08
DE4140475C2 (en) 1995-01-19
US5353492A (en) 1994-10-11
EP0546317B1 (en) 1995-02-15
DE59201411D1 (en) 1995-03-23

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