EP0709937A2 - Stirnkollektor und dessen Herstellungsverfahren - Google Patents

Stirnkollektor und dessen Herstellungsverfahren Download PDF

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Publication number
EP0709937A2
EP0709937A2 EP95402408A EP95402408A EP0709937A2 EP 0709937 A2 EP0709937 A2 EP 0709937A2 EP 95402408 A EP95402408 A EP 95402408A EP 95402408 A EP95402408 A EP 95402408A EP 0709937 A2 EP0709937 A2 EP 0709937A2
Authority
EP
European Patent Office
Prior art keywords
disc
annular
conducting
lamellae
commutator
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP95402408A
Other languages
English (en)
French (fr)
Other versions
EP0709937A3 (de
Inventor
Leonid Verbitsky
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Costar Ltd
Original Assignee
Costar Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Costar Ltd filed Critical Costar Ltd
Publication of EP0709937A2 publication Critical patent/EP0709937A2/de
Publication of EP0709937A3 publication Critical patent/EP0709937A3/de
Withdrawn legal-status Critical Current

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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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/04—Commutators
    • H01R39/06—Commutators other than with external cylindrical contact surface, e.g. flat commutators

Definitions

  • the present invention relates to end-face (or vertical) commutators of electric machines, more particularly, to small motor starter commutators for vehicles and especially to those intended to be used at high speed of rotation.
  • An end-face commutator for small motor starters usually constitutes an annular insulating housing containing a ring made of a conductive material in which radial grooves are stamped to define the commutator laminations (lamellae).
  • the conductive ring is embedded in the insulating annular housing in such a manner that the working side surface is left free and may be contacted by brushes of the motor, whilst the rear surface of the ring is covered by the material of the housing so as to keep the lamellae retained therein.
  • FR patent 1456598 discloses construction of an end face type collector (commutator) comprising an insulating housing with a conductive disc.
  • the disc is provided at its rear side with a retaining element in the form of an annular groove having sloped side walls.
  • a groove being provided in the working body of the disc, reduces strength and the service life of the collector.
  • DE patent 1101601 describes an end-face type commutator comprising a plastic annular housing incorporating therein a plurality of conductive lamellae arranged in a disc and shaped each so as to be engaged by its burred rear surface with the body of the housing.
  • a burr is annular and has a dovetail shape in its cros-section.
  • the height of the burr has to be comparable with the thickness of the disc, however this increases the commutator's, weight.
  • a number of subsequent steps and special instruments are required for manufacture of the dovetail-shaped burr, and therefore such an operation is expensive and time consuming.
  • the dovetail-shaped burr is not rigid enough due to its tiny size; it can be therefore easily crushed during molding the disc in the insulating housing. If such a defect takes place, this will definitely lead to reduction of the mechanical strength of the commutator. More particularly, at high speeds the coupling between the lamellae and the housing appears to be weak, i.e. it does not stand the axial and radial forces developing during rotation, and the lamellae with time are likely to drop out from the commutator.
  • the commutator comprises a conducting disc divided into lamellae by radial grooves and molded in an insulating housing. From its working surface, the disc is secured in the housing by an annular plate being an integral part of the housing. This annular plate prevents the lamellae from axial displacement during rotation of the commutator.
  • the conducting disc is provided with an annular protrusion situated on its rear surface and having a rectangular cross-section. Such a rectangular flange is supposed to improve the coupling between the conducting disc and the body of the insulating housing.
  • the conducting annular disc is placed into an annular form, and the form is then filled from its top with a plastic insulating material in which the disc is to be pressed in. It has been found that the insulating material often does not properly fill all narrow slots between the conducting disc and the annular form, therefore after complete molding of the commutator its housing may have inner defects.
  • An additional object of the invention is to provide a process of manufacturing of the novel commutator.
  • an end-face type commutator especially useful for motor starters, and comprising a conducting annular disc having a front and a rear sides and a central passage, said disc being divided into a plurality of lamellae by radial through slots; the annular conducting disc is coaxially embedded in an insulating annular housing and retained therein at its front and rear sides in such a manner, as to prevent the lamellae both from axial and radial displacement during rotation of the commutator; the arrangement being such that from its front side the disc is secured by an insulating annular collar having the outer diameter greater than the diameter of the central passage of said disc and constituting an integral part of the housing, and from the rear side said conducting disc is provided with an outer and an inner annular protrusions forming a coupling between the lamellae of the conducting disc and the insulating housing; said outer annular protrusion having a rectangular cross-section and being provided substantially along the outer circumference of the annular conducting disc, whil
  • the above-mentioned additional inner protrusion must be flanged (i.e. made by stretching of the metal) and not provided, say, by a cutting die.
  • the protrusions effected by the cutting (or punching) die come out fragile because they consist of portions of the shifted metal, and thus cannot form a reliable coupling with the insulating housing in the commutator.
  • said insulating annular collar is situated in a correspondingly shaped recess flanged along the inner circumference of the front side of the conducting annular disc, and may slightly project therefrom.
  • a process of manufacturing of the above described end-face type commutator including the following steps: a step of die-stamping of an annular conducting disc from a metal blank in such a manner as to obtain said conducting disc having an outer annular protrusion on its rear side; a step of dissecting said conducting disc by through slots into a plurality of radial lamellae though leaving thereof connected to each other by a circular edge portion of the conducting disc; a step of flanging an inner annular protrusion on the rear side of said conducting disc in such a manner as to put the inner passage of said conducting disc into a frusto-conical shape; a step of placing said conducting annular disc into a preheated annular form, followed by a step of filling the form with an insulating material and molding the disc therein, the form being continuously heated; a step of removing the molded commutator from the form; a step of severing the annular edge portion of the
  • said inner annular protrusion on the rear side of said conducting disc is flanged simultaneously with flanging of the annular recess along the inner circumference of the front side of the conducting disc.
  • said annular conducting disc may be formed from an annular metal blank, such as a pipe section.
  • FIGs 1A and 1B are represented two modifications of the end-face commutator of small starter motor which are described in the SU author's certificate No 650140.
  • a commutator 10 shown in Fig. 1A comprises a conducting disc 12 divided into lamellae by radial grooves (not shown) and molded in an insulating housing 11.
  • the disc 12 is secured in the housing 11 by an annular plate 15 constituting an integral part of the housing and intended to prevent displacement of the lamellae due to the axial forces which develop during rotation of the commutator.
  • the conducting disc 12 has an additional recess 17 provided at the inner circumferential portion of its front side 13.
  • the insulating annular plate 15 occupies the whole recess 17 and does not project from the front side of the disc.
  • the conducting lamellae of the disc 12 are embedded in the plastic housing 11 in such a manner that their front sides 13 are free and adapted to be contacted by electrical brushes of the associated motor.
  • the conducting disc 12 is provided with an annular protrusion (flange) 16 situated on its rear side 14 and having a rectangular cross-section. The rectangular shape of the flange 16 improves the coupling between the conducting disc 12 and the body of the insulating housing 11.
  • a rim 26 having a rectangular cross-section is provided at inner circumferential portion of the rear side of the disc 22.
  • the rim 26 is formed by shifting the metal from the front side of the disc 22 during manufacture of a recess 27.
  • Such a manner of providing the rim 26 results in its weak and fragile neck, which fact negatively affects the strength of the commutator. It is understood for those skilled in the art, that the thinner is the disc 22, the weaker is the neck of the rim 26, and therefore such a construction is inapplicable for small commutators intended to be used at high speed of rotation.
  • the conducting discs 12 or 22 are placed in forms on their front surfaces. It has been noted that the insulating material supposed to pass through the narrow passage 19 or 29 and form the annular plate 15 or 25, often does not properly fill these cavities, thus reducing the quality of the commutator.
  • An end-face type commutator 30 comprises an annular insulating housing 31 incorporating therein a conducting annular disc 32 having a front side 33, a rear side 34 and a central passage 40.
  • the disc 32 is divided into a plurality of lamellae (marked by the same numeral 32) by through radial grooves, which are not seen on the radial cross-section.
  • the annular conducting disc 32 is coaxially embedded and retained in the insulating annular housing 31 in the following way: from its front side 33 the disc 32 is secured in the housing by an insulating annular collar 35, and from its rear side 34 the conducting disc is provided with a pair of outer 36 and inner 38 annular protrusions forming a reliable coupling between the lamellae of the disc 32 and the insulating housing 31.
  • the annular collar 35 constitutes an integral part of the housing 31 and prevents axial displacement of the lamellae 32 during rotation of the commutator 30.
  • the insulating annular collar 35 is situated in a correspondingly shaped recess 37 flanged along the inner circumference of the front side 33 of the conducting disc.
  • the coupling formed between the housing 31 and the protrusions 36 and 38 prevents the lamellae 32 from radial displacement and dropping out from the housing.
  • the outer annular protrusion 36 has a rectangular cross-section and is provided substantially along the outer circumference of the annular conducting disc, whilst the inner annular protrusion 38 is formed along the central passage 40 of the annular disc 32. It can be seen, that the protrusion 38 is flanged in such a manner as to form with the central passage the shape of a truncated cone narrowing towards the front side 33 of the disc 32.
  • the protrusion 38 and the frusto-conical central passage 40 of the disc serve as an in-built funnel which facilitates penetration of the insulating material to the bottom portion of the annular form, thus rendering more rigidity to the molded commutator.
  • the described end-face type commutator can be manufactured in the following manner.
  • the annular conducting disc 32 may be formed by die-stamping from a metal pipe section in such a manner as to obtain the disc having the outer annular protrusion 36 on its rear side 34.
  • the disc 32 is then dissected into a plurality of radial lamellae though leaving thereof connected to each other only by a circular edge portion (not seen in Fig.2).
  • the inner annular protrusion 38 is flanged on the rear side 34 of the conducting disc 32 in such a manner as to put the inner. passage 40 of the disc into a frusto-conical shape.
  • the inner annular protrusion 38 may be flanged simultaneously with flanging of an annular recess 37 which can be seen in Fig.2 along the inner circumference of the front side 33 of the conducting disc.
  • the disc 32 is placed into a preliminarly heated annular form (not shown), which is then filled with an insulating material.
  • the disc 32 is molded in the form which is constantly being heated during this molding process. When the molded commutator is removed from the form, the annular edge portion of the conducting disc should be cut away so as to electrically separate the lamellae one from another. After that, a contact hollow (not seen) has to be provided in each of the separated lamellae in order to connect thereof to electric wires.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
EP95402408A 1994-10-26 1995-10-26 Stirnkollektor und dessen Herstellungsverfahren Withdrawn EP0709937A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IL11140694 1994-10-26
IL11140694A IL111406A0 (en) 1994-10-26 1994-10-26 End face type commutator for starters and process of manufacturing thereof

Publications (2)

Publication Number Publication Date
EP0709937A2 true EP0709937A2 (de) 1996-05-01
EP0709937A3 EP0709937A3 (de) 1996-10-30

Family

ID=11066693

Family Applications (1)

Application Number Title Priority Date Filing Date
EP95402408A Withdrawn EP0709937A3 (de) 1994-10-26 1995-10-26 Stirnkollektor und dessen Herstellungsverfahren

Country Status (2)

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EP (1) EP0709937A3 (de)
IL (1) IL111406A0 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004054074A1 (ja) 2002-12-10 2004-06-24 Mitsuba Corporation 偏平型コンミテータ製造方法及び偏平型コンミテータ製造装置

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1101601B (de) 1957-10-12 1961-03-09 Bosch Gmbh Robert Plankollektor
FR1456598A (fr) 1965-07-12 1966-07-08 Mavilor Procédé de fabrication des collecteurs plats pour moteurs électriques et machines électriques, et les collecteurs obtenus par la mise en oeuvre de ce procédé
SU650140A1 (ru) 1975-03-14 1979-02-28 Предприятие П/Я В-2358 Торцовый коллектор

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB738823A (en) * 1952-06-24 1955-10-19 Hoover Ltd Improvements relating to commutators
ZA733925B (en) * 1972-06-20 1974-05-29 Lucas Electrical Co Ltd Commutators
FR2624315B1 (fr) * 1987-12-07 1990-04-13 Equip Electr Moteur Collecteur frontal pour machine electrique tournante

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1101601B (de) 1957-10-12 1961-03-09 Bosch Gmbh Robert Plankollektor
FR1456598A (fr) 1965-07-12 1966-07-08 Mavilor Procédé de fabrication des collecteurs plats pour moteurs électriques et machines électriques, et les collecteurs obtenus par la mise en oeuvre de ce procédé
SU650140A1 (ru) 1975-03-14 1979-02-28 Предприятие П/Я В-2358 Торцовый коллектор

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004054074A1 (ja) 2002-12-10 2004-06-24 Mitsuba Corporation 偏平型コンミテータ製造方法及び偏平型コンミテータ製造装置

Also Published As

Publication number Publication date
EP0709937A3 (de) 1996-10-30
IL111406A0 (en) 1994-12-29

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