EP1568110B1 - Plankommutator - Google Patents

Plankommutator Download PDF

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Publication number
EP1568110B1
EP1568110B1 EP04790810A EP04790810A EP1568110B1 EP 1568110 B1 EP1568110 B1 EP 1568110B1 EP 04790810 A EP04790810 A EP 04790810A EP 04790810 A EP04790810 A EP 04790810A EP 1568110 B1 EP1568110 B1 EP 1568110B1
Authority
EP
European Patent Office
Prior art keywords
contact
segments
carbon
annular
conductor
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.)
Expired - Lifetime
Application number
EP04790810A
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German (de)
English (en)
French (fr)
Other versions
EP1568110A1 (de
Inventor
Joze Potocnik
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.)
Kolektor Group doo
Original Assignee
Kolektor Group doo
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 Kolektor Group doo filed Critical Kolektor Group doo
Priority to SI200430300T priority Critical patent/SI1568110T1/sl
Priority to PL04790810T priority patent/PL1568110T3/pl
Publication of EP1568110A1 publication Critical patent/EP1568110A1/de
Application granted granted Critical
Publication of EP1568110B1 publication Critical patent/EP1568110B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00Rotary current collectors, distributors or interrupters
    • H01R39/02Details for dynamo electric machines
    • H01R39/04Commutators
    • H01R39/06Commutators other than with external cylindrical contact surface, e.g. flat commutators
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06Manufacture of commutators
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00Rotary current collectors, distributors or interrupters
    • H01R39/02Details for dynamo electric machines
    • H01R39/04Commutators
    • H01R39/045Commutators the commutators being made of carbon
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06Manufacture of commutators
    • H01R43/08Manufacture of commutators in which segments are not separated until after assembly
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49009Dynamoelectric machine
    • Y10T29/49011Commutator or slip ring assembly

Definitions

  • the present invention relates to a flat commutator with a made of insulating molding carrier body, a plurality of evenly around the commutator arranged around conductor segments and an equally large number of positively connected to the conductor segments electrically conductively connected, consisting of monocarbon, the brush surface defining carbon segments, each one of the brush tread opposite arranged, annular projection.
  • Plankommutatoren whose Bürstenlauf requirements is defined by the face of carbon segments, come instead of commutators with a metallic brush surface in particular in a corrosive environment used, such as drive motors of fuel pumps in motor vehicles.
  • Corresponding plan commutators count in many different versions of the prior art. Reference may be made in this connection, for example, to DE 8908077 U1, EP 583892 B1, EP 1001501 B1, US Pat. No. 5,175,463 A1, DE 9807045 U1, DE 19752626 A1, US Pat. No.
  • the projecting from the conductor segments end portions of those projections are mechanically deformed by a compression in order to achieve the most rigid possible jamming of the carbon segments on the conductor segments.
  • the carbon segments are made up of two layers of different material composition in that the projections and the respectively adjacent regions of the carbon segments, unlike the regions adjacent to the brush tread, consist of a metal-containing carbon. This not only favors the deformability of the protrusions but also the current density distribution within the carbon segments.
  • the production of such two-layer carbon elements is comparatively expensive. This disadvantage does not exist in the known generic plan commutators with carbon segments of "monocarbon".
  • due to the small-area effective contacting of the carbon segments with the conductor segments there is an unfavorable current density distribution which leads to overloading of the contacting.
  • the present invention aims to provide a plan commutator of the type specified, which avoids the disadvantages mentioned above.
  • the corresponding plan commutator despite its manufacturability with relatively small dimensions and at comparatively low cost, should have a favorable current density distribution at the transition from the conductor segments to the carbon segments and a long service life.
  • a feature characteristic of plank commutators according to the invention is the above-described contacting of each carbon segment with the associated conductor segment in the region of at least three surfaces, namely the outer peripheral surface, the annular end surface and the inner peripheral surface of the annular projection and, if necessary, additionally the base of the bore of the carbon segment.
  • this permits a particularly large-area contacting of the carbon segments with the conductor segments; as a result, there is a particularly favorable current density distribution at the transition from the conductor segments to the carbon segments and within the carbon segments, even if they are low cost as so-called.
  • the plastic deformation of the annular projections of the carbon segments may in particular include penetration of the edge regions of the contact rings and the contact pins of the conductor segments in the original contour of the annular projections, wherein a possible superficial metallization of the carbon segments is scraped off here by the contact rings and contact pins, so that a direct contact of the carbon material with the respective contact ring and pin is possible.
  • the elastic bias utilizes the modulus of elasticity of the cured carbon of the preformed and precured annular protrusions of the carbon segments.
  • the bias in question is constructed in two stages, namely on the one hand when joining the conductor segments and the carbon segments and then when the full closing force is applied to the mold in question before spraying the carrier body.
  • the carbon segments have no superficial metallization according to a preferred development of the invention, a gap-free, prestressed direct contact between the carbon material of the carbon segments and the respective conductor segment is possible by the elastic deformation of the projections (see also) in the area of the end faces of the projections. This gap-free end face contact of the projections of the carbon segments to the associated contact surfaces of the conductor segments may be of particular importance.
  • plan commutator according to the invention according to claim 1 proves to be particularly favorable that the contacting of the carbon segments with the conductor segments in the region of the end faces of the projections is also particularly well protected against aggressive media which can diffuse through the molding material of the carrier body; because the respective contact is in each case, apart from possible narrow Preßstoffkanälen (s.u.), Shielded from the carrier body on all sides by the voltage applied to the outer surface of the annular projection of the carbon segment or penetrating into the projection contact ring of the conductor segment.
  • Plankommutatoren is characterized in that the connection to the carbon segments serving surfaces of the contact rings of the conductor segments whose annular contact surfaces and the outer peripheral surfaces and, if necessary. End faces of the contact pins with an oxidation and corrosion resistant metal such as silver, Tin or the like are coated.
  • an oxidation and corrosion resistant metal such as silver, Tin or the like
  • the end faces of the annular projections and the surfaces of the carbon segments surrounding the annular projections have an interconnected metallization, preferably a galvanic metallization.
  • a metallization may be double-layered with a base layer of copper (e.g., 4 to 12 microns) and a capping layer of tin (e.g., 2 to 6 microns). Since the metallization extends in each case onto the surfaces of the carbon segment surrounding the annular projection, a large-area introduction of the current into the carbon segments results and thus a particularly favorable current flow distribution within the carbon segments.
  • each contact ring in the region of its connection to the associated Carbon segment serving surface has at least one Preßstoffkanal which ends in the region of the edge formed by the respective surface and the annular contact surface.
  • a first contact is made via the inner surfaces of the contact rings and the outer surfaces of the contact pins, which penetrate in the assembly of carbon ring disc and conductor blank in the carbon mass of the annular projections;
  • the metallization of the carbon segments is sheared off there by the penetrating contact rings or contact pins.
  • a second contact is made via the connected to the contact surfaces of the conductor segments via an electrically conductive intermediate layer end faces of the annular projections of the carbon segments, from here the current over the above-described current-conducting strips and the metallization of the protrusions surrounding areas of the carbon segments over a large area in this is initiated.
  • an electrically conductive intermediate layer is arranged between the superficially metallized end faces of the annular projections of the carbon segments and the associated contact surfaces of the conductor segments.
  • Their function is in particular to equalize the surface roughness of the end faces of the projections of the carbon segments and the contact surfaces of the conductor segments and in this way, even with practical manufacturing tolerances for the conductor segments and the carbon segments a large-scale contact of the front - in the surface metallization virtually non-deformable - carbon segments to favor with the conductor segments.
  • a solder joint between the metallized end faces of the annular projections of the carbon segments and the associated contact surfaces of the conductor segments can be produced via the intermediate layer.
  • the electrically conductive intermediate layer prevents by equalization of the surface roughness on the two surfaces mentioned a penetration of molding material in the contact zone in question during the spraying of the carrier body.
  • this preferably consists of a first powdery or pasty, compressed during the assembly of carbon ring and conductor blank, electrically conductive material, in particular in the form of a thus compacted metal powder, for example, tin, a compressed graphite powder, a compacted mixed powder of metal and graphite or a hardened solder paste.
  • the thickness of the intermediate layer may be in particular cases of application of the invention, in particular between 0.03 and 0.1 mm. Manufacturing technology, it is particularly advantageous if the later intermediate material forming material is applied to the end faces of the projections of the carbon segments, for example by means of a tampon.
  • the carbon segments with the conductor segments electrically connecting connecting regions are each surrounded by an annular, arranged between the carbon segments and the conductor segments Preßstoff Anlagen.
  • Those annular Preßstoff Anlagenen shield the connecting portions of the carbon segments with the conductor segments to the outside, so that they are protected from direct contact with aggressive media. This development also proves to be particularly favorable in the case of use of the commutator in a problematic environment.
  • the planar commutator according to the invention is characterized in that the conductor segments have annular elevations arranged opposite the annular contact surfaces and engaging in the carrier body. This is favorable both with regard to the production of the commutator and with regard to its use.
  • the annular contact surfaces of the conductor segments can be produced particularly inexpensively and efficiently by axially displacing material of the conductor segments in such a way that they are on the opposite side, while these are still connected to one another to form a conductor blank forms said annular elevations.
  • These annular elevations are then embedded in the course of the further manufacturing process in the molding material of the carrier body, which favors a particularly mechanically strong anchoring of the conductor segments in the carrier body and in this way the life of the commutator.
  • the annular projections have a substantially trapezoidal basic shape, wherein this definition should also include those projections in which the radial outer boundary has a substantially arcuate course. This results in a particularly favorable utilization of the available for the mechanical connection and electrical contacting of the carbon segments with the conductor segments area at a particularly pronounced strength of the compound.
  • the structural design in detail for example, the size of the commutator and the exact composition of the preparation of the carbon segments, namely the corresponding Projections, material used can depend.
  • the surfaces of the contact rings serving for connection to the carbon segments may be conical, in particular by tapering in the direction of the annular contact surface; However, they are preferably made cylindrical.
  • the annular projections of the carbon segments preferably have a frusto-conical outer contour; However, they could also be cylindrical.
  • the contact pins may preferably have a substantially round cross-section; but also other cross-sectional shapes come into consideration, especially when the outer peripheral surface of the annular recess deviates particularly strongly from a circular shape.
  • the contact pins are preferably made cylindrical; however, this too is not mandatory.
  • the method used for the production of plan commutators according to the present invention corresponds to those methods known from the prior art (eg DE 19956844 A1).
  • the relevant process steps are the separate production of a conductor blank, which in its final configuration interconnected conductor segments with the contact rings, annular contact surfaces and contact pins comprises, and one of the above-described annular projections having carbon ring disk.
  • Conductor blank and carbon ring are then joined together axially, wherein the annular projections of the carbon ring ring on the one hand and the contact rings and pins of the conductor segments of the conductor blank on the other mechanically engage with each other, and axially pressed together to produce a permanent connection (see above).
  • This unit is then encapsulated with a molding material forming Preßstoffmasse.
  • the carbon ring disk is divided into the individual carbon segments by mechanical processing and the connections of the individual conductor segments of the conductor blank are separated.
  • plan commutator comprises a made of insulating molding material Carrier body 1, eight evenly distributed around the axis 2 around arranged conductor segments 3 and eight carbon segments 4, each of which is electrically connected to each one conductor segment 3.
  • the carbon segments 4 together define a brush running surface 5 which is perpendicular to the commutator axis 2.
  • the carrier body 1 has a central bore 6.
  • the existing copper conductor segments 3 have emerged from a common conductor blank. They each comprise a connection region 7 and a contact region 8. A contact lug 9 is arranged in each case on the connection region 7. This serves the electrically conductive connection of a winding wire of a rotor winding with the relevant conductor segment 3.
  • To better anchor the conductor segments 3 in the carrier body 1 is from the terminal portions 7 of each conductor segment 3 obliquely inwardly before a holding claw 10.
  • the carbon segments 4 are each covered by a Preßstoffmantel 11 of the support body 1 at their radially outer peripheral surfaces. In this case, by a stepped design of the outer peripheral surface of the carbon segments 4 a positive connection to the respective Preßstoffmantel 11.
  • the molding material of the carrier body 1 in the form of a Preßstoffkragens 12 also covers the radially inner peripheral surfaces of the carbon segments 4. Again, there is a result of a stepped execution of radially inner peripheral surfaces of the carbon segments 4 a positive connection.
  • the form-fitting connections of the carbon segments 4 with the carrier body 1 in the region of their radially inner and outer peripheral surfaces ensures permanent retention of the carbon segments in the carrier body 1.
  • plan commutator according to the drawing corresponds to the prior art (eg DE 19956844 A1), so that the basic structure need not be explained in more detail.
  • each carbon segment 4 has an annular projection 13 with a bore 14.
  • Each projection 13 rests with its annular end face 15 against a corresponding annular contact surface 16 of the associated conductor segment 3.
  • the contact surface 16 is in each case surrounded by a closed contact ring 24, which electrically conductively abuts against the outer peripheral surface 23 of the associated annular projection 13 or partially penetrates into this.
  • each carbon segment 4 is electrically connected to the associated conductor segment 3 over four surfaces, namely via the outer peripheral surface 23, the annular end surface 15 and the inner peripheral surface 19 of the annular one Projection 13 and the standing with the end face 20 of the contact pin 17 in contact base 21 of the bore 14th
  • the contacting with the carbon segment serving surfaces of the conductor segment 3 are each with a coating 25 of an oxidation and corrosion resistant metal such as tin, silver or the like coated.
  • the connecting regions 26, which each electrically connect the carbon segments 4 to the conductor segments 3, are each surrounded by an annular precursor layer 27 arranged between the carbon segments and the conductor segments. Also filled with molding material are those cavities 28, each in the region of the formed by the inner surface 29 of the contact ring 24 and the annular contact surface 16 edge 30 between the conductor segment 3 and - rounded here (see Fig .. 4) - projection 13 of the carbon segment 4 exist.
  • the inner surfaces 29 of the contact rings 24 of the conductor segments 3 have, in their radially outer section 31, respectively two press-material channels 32 (see FIG. 3), each terminating in the region of the edges 28.
  • the conductor segments 3 have on their side facing away from the associated carbon segment 4 on an annular, the annular contact surface 16 opposite and corresponding to this elevation 33.
  • These annular elevations which were each formed by axial displacement of the material pressed to produce the associated annular contact surface 16, engage in the carrier body 1.
  • FIG. 4 illustrates that the outer peripheral surfaces 23 of the annular projections 13 of the carbon ring disc 35 prior to their assembly with the Conductor blank are inclined such that the projections taper slightly towards the end face 15.
  • the comparison of this representation of the carbon ring disc 35 before its joining with the conductor blank with the representations of the finished flat commutator, in particular Fig. 2, illustrates the partial penetration of the contact ring 24 in the annular projection 13 in the region of the outer peripheral surface 23 and the plastic thereby caused Deformation of the relevant projection in this area.
  • the contact pin 17 penetrates easily into the bore 14 surrounding carbon material.
  • the carbon segments 4 each have a superficial galvanic metallization 37.
  • the metallization Prior to joining the carbon ring to the conductor blank, the metallization extends over the base 21 of the bore 14, the entire surfaces of the annular projection 13, and the surface of the respective carbon segment adjacent to the projection 13.
  • the metallization 37 is made of two layers with a base layer of copper and a covering layer of tin.
  • each of the contact ring 24 and the contact pin 17 shears off the metallization 37 and penetrates into the non-metallized carbon material.
  • the metallization 37 of the carbon segments 4 remains intact, so that the regions 39 of the metallization 37 lying outside of the projections 13 are electrically conductive Strip 40, which extend within the Preßstoffkanäle 32 and consist of the left there standing metallization, are connected to the metallization 37 in the region of the end face 13.
  • the interruption of the metallization 37 by the partial penetration of the contact rings 24 in the projections 13 is thus without adverse effects in terms of the current flow distribution within the carbon segments.
  • an electrically conductive intermediate layer 38 is illustrated, which is respectively disposed between the end face 15 of the projections 13 of the carbon segments 4 and the contact surface 16 of the conductor segments 3 and due to a leveling of the surface roughness of both surfaces concerned for a large-area contact between the carbon segments 4 and the conductor segments 3 without air and / or Preßstoff inclusions in the contact zone provides.
  • each annular projection 13 is assigned a total of five molding channels 32, which are arranged radially outside, radially inside and at the two surfaces of the contact ring 24 extending parallel to the radial sections 34. This depends on the function of the current-conducting strips 40 running there (see above).
  • the illustrated in Fig. 8 third embodiment of the Plankommutators differs from that of Figures 5 to 7 essentially only in that the conductor segments 3 'each have four contact projections 22 instead of a contact ring. These surround the annular projections 13 ', engage in the region of the outer peripheral surfaces 23' of the annular projections 13 'electrically conductive in the carbon material and are separated from each other by openings 36. In the area of the mentioned breakthroughs 36 between in each case two adjacent contact projections 22, the molding material of the carrier body 1 'abuts the (metallised) outer peripheral surface 23' of the annular projection 13 'of the associated carbon segment 4'. Here, the remaining metallization again forms electrically conductive strips 40 ', as well as in the region of the two Preßstoffkanäle 32'.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Contacts (AREA)
  • Linear Motors (AREA)
  • Rotary Switch, Piano Key Switch, And Lever Switch (AREA)
EP04790810A 2003-12-17 2004-10-24 Plankommutator Expired - Lifetime EP1568110B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
SI200430300T SI1568110T1 (sl) 2003-12-17 2004-10-24 Ploski komutator
PL04790810T PL1568110T3 (pl) 2003-12-17 2004-10-24 Komutator płaski

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10359473 2003-12-17
DE10359473A DE10359473B4 (de) 2003-12-17 2003-12-17 Plankommutator
PCT/EP2004/012020 WO2005062431A1 (de) 2003-12-17 2004-10-24 Plankommutator

Publications (2)

Publication Number Publication Date
EP1568110A1 EP1568110A1 (de) 2005-08-31
EP1568110B1 true EP1568110B1 (de) 2007-02-28

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ID=34683523

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04790810A Expired - Lifetime EP1568110B1 (de) 2003-12-17 2004-10-24 Plankommutator

Country Status (18)

Country Link
US (1) US7019432B1 (pt)
EP (1) EP1568110B1 (pt)
JP (1) JP4435175B2 (pt)
KR (1) KR101034174B1 (pt)
CN (1) CN100421314C (pt)
AT (1) ATE355640T1 (pt)
BR (1) BRPI0406653B1 (pt)
DE (2) DE10359473B4 (pt)
DK (1) DK1568110T3 (pt)
ES (1) ES2282913T3 (pt)
HK (1) HK1083153A1 (pt)
MX (1) MXPA05006707A (pt)
PL (1) PL1568110T3 (pt)
RU (1) RU2343609C2 (pt)
SI (1) SI1568110T1 (pt)
TW (1) TWI263382B (pt)
UA (1) UA82079C2 (pt)
WO (1) WO2005062431A1 (pt)

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CN101924315B (zh) * 2009-06-16 2014-09-03 德昌电机(深圳)有限公司 换向器及其制造方法
DE102009057063A1 (de) * 2009-12-04 2011-06-09 Kolektor Group D.O.O. Verfahren zur Herstellung eines Plankommutators sowie Plankommutator
CN103269004A (zh) * 2012-12-26 2013-08-28 宁波华瑞电器有限公司 一种石墨换向器
CN104283085B (zh) * 2014-10-29 2016-07-06 瑞安市双峰换向器有限公司 一种换向器
CN107204557A (zh) * 2016-03-17 2017-09-26 德昌电机(深圳)有限公司 换向器、使用该换向器的电机及换向器的制备方法
CN111082607B (zh) * 2018-10-22 2024-09-06 株式会社电装 电接触装置和包括电接触装置的旋转电机

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CN2580644Y (zh) * 2002-11-16 2003-10-15 浙江利丰电器股份有限公司 全塑平面换向器

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101055962B (zh) * 2007-05-28 2010-08-04 史文浩 圆筒式碳换向器及其制造方法

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ES2282913T3 (es) 2007-10-16
HK1083153A1 (en) 2006-06-23
RU2343609C2 (ru) 2009-01-10
DE10359473A1 (de) 2005-07-21
EP1568110A1 (de) 2005-08-31
KR20060106869A (ko) 2006-10-12
MXPA05006707A (es) 2005-09-08
TW200525837A (en) 2005-08-01
TWI263382B (en) 2006-10-01
DE10359473B4 (de) 2006-08-03
DK1568110T3 (da) 2007-03-26
KR101034174B1 (ko) 2011-05-12
SI1568110T1 (sl) 2007-08-31
CN1723593A (zh) 2006-01-18
BRPI0406653B1 (pt) 2016-12-20
RU2005123797A (ru) 2006-04-10
CN100421314C (zh) 2008-09-24
PL1568110T3 (pl) 2007-07-31
US7019432B1 (en) 2006-03-28
JP4435175B2 (ja) 2010-03-17
WO2005062431A1 (de) 2005-07-07
UA82079C2 (en) 2008-03-11
BRPI0406653A (pt) 2005-12-06
DE502004003031D1 (de) 2007-04-12
ATE355640T1 (de) 2006-03-15

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