EP2481131B1 - Commutator for power transmission in an electric machine - Google Patents

Commutator for power transmission in an electric machine Download PDF

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Publication number
EP2481131B1
EP2481131B1 EP10755172.3A EP10755172A EP2481131B1 EP 2481131 B1 EP2481131 B1 EP 2481131B1 EP 10755172 A EP10755172 A EP 10755172A EP 2481131 B1 EP2481131 B1 EP 2481131B1
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EP
European Patent Office
Prior art keywords
metal
collector
brush
commutator
layer
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Not-in-force
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EP10755172.3A
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German (de)
French (fr)
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EP2481131A1 (en
Inventor
Jan Goehler
Michael Bayer
Antje Winkelmann
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Robert Bosch GmbH
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Robert Bosch GmbH
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Priority to PL10755172T priority Critical patent/PL2481131T3/en
Publication of EP2481131A1 publication Critical patent/EP2481131A1/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
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/04—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
    • H01R39/022—Details for dynamo electric machines characterised by the materials used, e.g. ceramics
    • H01R39/025—Conductive materials
    • 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
    • H01R39/18—Contacts for co-operation with commutator or slip-ring, e.g. contact brush
    • H01R39/20—Contacts for co-operation with commutator or slip-ring, e.g. contact brush characterised by the material thereof
    • 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/12—Manufacture of brushes

Definitions

  • the invention relates to a commutator for power transmission in an electrical machine according to the preamble of claim 1.
  • Commutators are used for power transmission to the rotor mounted in a rotating manner in a stator and for current application in short-circuited armature coils, consisting of an armature-side collector and brushes adjacent to the collector.
  • the housing-fixed carbon brushes are applied to the lateral surface of the rotating collector, wherein the material properties of Kommutator ister has a significant influence on the power transmission rate of the carbon brush on the collector and on the wear, in particular the carbon brush.
  • a metal-filled carbon brush for a small motor which is designed as a sintered component and consists of a cleaned graphite powder, which is mixed with metal powder, compression-molded and then sintered.
  • the invention has the object of providing a commutator in an electrical machine in such a way that on the one hand a high power transmission and on the other a long life is guaranteed.
  • the commutator according to the invention is used for power transmission and current application in electrical machines, in particular in electric motors, both use in DC motors and in AC motors is considered.
  • such commutators can be used in DC starter motors for internal combustion engines, which are designed either as electric or permanent-magnet motors and can be used both for gasoline engines and for diesel engines.
  • start-stop systems for internal combustion engines or use as an electric machine in hybrid vehicles come into consideration.
  • Further possible uses are electric drives, in particular as a servomotor in vehicles, for example for engine cooling, vehicle air conditioning or as a windscreen wiper motor.
  • a use in electric motors for power tools is possible.
  • a use in slip-ring asynchronous motors and three-phase generators with high robustness and durability is conceivable.
  • the commutator comprises an armature-side collector which is fixedly coupled to the armature of the electric machine, and at least one brush fixed to the housing, via which the current is transmitted to the collector for energizing armature coils.
  • At least one current-transmitting component of the commutator is designed as a porous ceramic body with infiltrated metal.
  • the porous ceramic body is a preform that is infiltrated with molten metal during the manufacturing process, for example by gas pressure infiltration or squeeze-cast technology.
  • the current-carrying component of the commutator embodied in this way thus consists of a metal-ceramic composite material which is designed as a preform-based material (P-MMC) or produced in this way.
  • the ceramic content in the composite ensures high resistance to wear and corrosion, and high temperature resistance is achieved (up to 800 ° C when using Cu as a metallic component).
  • the ceramic component reduces the friction during the relative movement between brush and collector shell surface, so that the wear resistance is increased.
  • Another advantage is that even larger components with complex geometries are completely infiltrated with the metal without cracking. As a result, both the brushes and the collector can be produced with the respective desired geometry.
  • At least one commutator component - one or more brushes and / or the collector - is made from the metal-ceramic composite material with the porous ceramic body with infiltrated metal.
  • Both variant embodiments, in which only the brushes or only the collector or both the brushes and the collector are made of the metal-ceramic composite material, are possible.
  • both the brush and the collector made of the composite material both the same composite materials and different composite materials for the brush and the collector can be used or the same or different mixing ratios of ceramic to metal content can be used.
  • Suitable ceramic components are oxides, nitrides or carbides, for example Al 2 O 3 , AlN, TiN, Si 3 N 4 , SiC or silicon-infiltrated SiC.
  • a metallic component preferably highly conductive materials are used, in particular copper or copper alloys, but also silver, gold, aluminum, iron, tin and their alloys.
  • lubricants and abrasives may be added as needed.
  • the composite material embodied as a porous ceramic body with infiltrated metal also has a high electrical and thermal conductivity in addition to the resistance to wear, temperature and corrosion that results from the ceramic component.
  • specific electrical resistances between about 0.05 ⁇ m and 10 15 ⁇ m can be generated.
  • the brush may be convenient to make the brush with multiple functional layers, each made as a metal-ceramic composite, but having a different metal or ceramic content.
  • the transition between these functional layers can optionally be discrete or continuous be.
  • the brush is designed, for example, with two layers with different metal content, the layer lying in the relative direction of movement having a higher metal content as the power layer and having a higher current transmission rate than the layer lying in the relative direction of movement forming a commutation layer.
  • the comparatively higher proportion of ceramic in the commutation layer allows commutation by means of a high tangential resistance and reduces the formation of sparks on the running edge of the brush.
  • the power layer which has a higher metal content, has a larger contact cross-section in relation to the commutation layer, in particular a greater thickness in the direction of movement, optionally also a greater width transversely to the direction of movement.
  • the larger contact area of the power layer allows higher power transfer rates.
  • the collector is made of a composite material with a relatively high metal content, which allows a high power transmission rate.
  • the composite material from which the collector is made can be constructed at least approximately the same as the composite material of the power layer in the brush, but it expediently has a higher metal content than the commutation layer.
  • the core of the collector can be represented as a dense ceramic insulator.
  • the ceramic precursor body is designed such that the later running surfaces of the collector consist of a freely selectable composition of metal and ceramic.
  • different mixing ratios ceramic to metal portion can be used axially along the segments of the collector to produce the electrical contact with the armature winding.
  • a production-related encapsulation on the brush as a brush plate, via which the electrical contacting by means of a rigid or flexible electrical conductor (eg strand) takes place.
  • the encapsulation represents a surface of the ceramic body at least partially covering layer, which can be used as a foot plate for holding and contacting the layers in the brush.
  • the in Fig. 1 shown commutator 1 is used for power transmission and current application in electrical machines such as electric motors or generators and comprises a cylindrical collector 2 which is rotatably connected to the armature of the electric machine, which is rotatably mounted in a stator, and brushes 3, which at the lie radially on the outer surface of the cylindrical collector 2 or on the disk running surface on contact and transmit electricity to the collector 2, which is passed through a strand 4 in the brush 3.
  • the collector 2 can also be designed as a disc.
  • Other contacts, such as metal bands or pressure springs are also possible.
  • the commutator 1 has two diametrically opposite brushes 3. In principle, however, come into consideration also commutators with a larger number of brushes, for example, four or six brushes.
  • the collector 2 has a plurality of individual, circumferentially separated segments 5, which are electrically connected to armature coils. During a rotary movement of the armature or the collector 2 in the direction of rotation 6, the lateral surface slides of the collector along the facing end face of the brushes 3, at the same time the power is transmitted from the brushes 3 to the segments 5 of the collector. 2
  • a section through a brush 3 is shown.
  • the power supply via the strand 4 or a comparable contacting is optionally carried out in a brush plate 7, which is a base plate and is connected to two layers 8 and 9 of the brush, which are formed as a power layer 8 and commutation 9.
  • the power layer 8 lies at the front and the commutation layer 9 at the rear, correspondingly 8a denotes the tapered edge (leading edge) of the brush 3 and 9a the trailing edge (trailing edge).
  • the power layer 8 in front of the commutation layer 9 comes into contact with the respective next segment 5 on the collector 2.
  • the frontal contact surface of the brush 3, which is in contact with the lateral surface of the collector is provided with reference numeral 10.
  • Both layers 8 and 9 of the brush 3 are made of a metal-ceramic composite material and are designed as a porous ceramic body with infiltrated metal (preform-based metal matrix composite - P-MMC).
  • This is a porous, ceramic preform, which is preferably infiltrated by pressurized gas pressure infiltration or molten metal squeeze-cast technology.
  • the front power layer 8 has a larger contact cross section than the rear commutation layer 9, so that in the region of the contact surface 10, the power layer 8 touches the outer surface of the collector over a larger area than the commutation layer 9.
  • the larger contact cross section is in particular by a larger width or thickness of the power layer 8 achieved, measured in the direction of relative movement.
  • the thickness of the power layer 8 is about twice as large as the thickness of the commutation layer 9.
  • the infusion represents a metal layer on the ceramic body outside and consists of the same material as the introduced into the ceramic body metal.
  • oxides, nitrides or carbides come into consideration, as the metal, copper or a copper alloy is preferably used. In consideration come as a metallic component but also other highly conductive metals such as silver, gold, aluminum, iron, tin and alloys thereof.
  • the power layer 8 and the commutation layer 9 differ with regard to their ceramic or metal content.
  • the power layer 8 has a higher metal content than the commutation layer 9, which improves the electrical conductivity of the power layer 8.
  • the commutation layer 9 is very wear and temperature resistant due to the higher ceramic content.
  • the sparking in the region of the trailing edge 9a is reduced due to the higher ceramic content.
  • Fig. 3 the collector 2 is shown in section.
  • the segments 5 on the outside of the collector 2, which are each separated in the circumferential direction from each other, are also made of a metal-ceramic composite material in the form of a porous ceramic body with infiltrated metal (P-MMC).
  • P-MMC porous ceramic body with infiltrated metal

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Motor Or Generator Current Collectors (AREA)

Description

Die Erfindung bezieht sich auf einen Kommutator zur Stromübertragung in einer elektrischen Maschine nach dem Oberbegriff des Anspruchs 1.The invention relates to a commutator for power transmission in an electrical machine according to the preamble of claim 1.

Stand der TechnikState of the art

Zur Stromübertragung auf den in einem Stator rotierend gelagerten Anker sowie zur Stromwendung in kurzgeschlossenen Ankerspulen werden Kommutatoren eingesetzt, bestehend aus einem ankerseitigen Kollektor und an dem Kollektor anliegenden Kohlebürsten. Die gehäusefesten Kohlebürsten liegen an der Mantelfläche des rotierenden Kollektors an, wobei die Materialbeschaffenheit der Kommutatorbestandteile einen wesentlichen Einfluss auf die Stromübertragungsrate von der Kohlebürste auf den Kollektor sowie auf den Verschleiß insbesondere der Kohlebürste hat.Commutators are used for power transmission to the rotor mounted in a rotating manner in a stator and for current application in short-circuited armature coils, consisting of an armature-side collector and brushes adjacent to the collector. The housing-fixed carbon brushes are applied to the lateral surface of the rotating collector, wherein the material properties of Kommutatorbestandteile has a significant influence on the power transmission rate of the carbon brush on the collector and on the wear, in particular the carbon brush.

Aus der DE 40 25 367 C2 ist eine metallgefüllte Kohlebürste für einen Kleinmotor bekannt, die als Sinterbauteil ausgeführt ist und aus einem gereinigten Graphitpulver besteht, das mit Metallpulver vermengt, druckgeformt und anschließend gesintert wird.From the DE 40 25 367 C2 For example, a metal-filled carbon brush for a small motor is known, which is designed as a sintered component and consists of a cleaned graphite powder, which is mixed with metal powder, compression-molded and then sintered.

Aus der EP-A-0501787 ist ein Stromkollektor gemäß dem Oberbegriff des Anspruchs 1 bekanntFrom the EP-A-0501787 a current collector according to the preamble of claim 1 is known

Offenbarung der ErfindungDisclosure of the invention

Der Erfindung liegt die Aufgabe zugrunde, einen Kommutator in einer elektrischen Maschine so auszubilden, dass zum einen eine hohe Stromübertragung und zum andern eine hohe Lebensdauer gewährleistet ist.The invention has the object of providing a commutator in an electrical machine in such a way that on the one hand a high power transmission and on the other a long life is guaranteed.

Diese Aufgabe wird erfindungsgemäß mit den Merkmalen des Anspruchs 1 gelöst. Die Unteransprüche geben zweckmäßige Weiterbildungen an.This object is achieved with the features of claim 1. The dependent claims indicate expedient developments.

Der erfindungsgemäße Kommutator wird zur Stromübertragung und Stromwendung in elektrischen Maschinen eingesetzt, insbesondere in Elektromotoren, wobei sowohl eine Verwendung in Gleichstrommotoren als auch in Wechselstrommotoren in Betracht kommt. Beispielsweise können derartige Kommutatoren in Gleichstrom-Startermotoren für Verbrennungsmotoren eingesetzt werden, die entweder als elektrisch oder als permanenterregte Motoren ausgeführt sind und sowohl für Ottomotoren als auch für Dieselmotoren eingesetzt werden können. In Betracht kommen darüber hinaus beispielsweise Start-Stopp-Systeme für Verbrennungsmotoren oder ein Einsatz als elektrische Maschine in Hybridfahrzeugen. Weitere Einsatzmöglichkeiten sind elektrische Antriebe, insbesondere als Stellmotor in Fahrzeugen, beispielsweise für die Motorkühlung, die Fahrzeugklimatisierung oder als Scheibenwischermotor. Darüber hinaus ist auch ein Einsatz in Elektromotoren für Elektrowerkzeuge möglich. Auch eine Verwendung in Schleifringläufer-Asynchronmotoren und Drehstromgeneratoren mit hoher Robustheit und Lebensdauer ist denkbar.The commutator according to the invention is used for power transmission and current application in electrical machines, in particular in electric motors, both use in DC motors and in AC motors is considered. For example, such commutators can be used in DC starter motors for internal combustion engines, which are designed either as electric or permanent-magnet motors and can be used both for gasoline engines and for diesel engines. In addition, for example, start-stop systems for internal combustion engines or use as an electric machine in hybrid vehicles come into consideration. Further possible uses are electric drives, in particular as a servomotor in vehicles, for example for engine cooling, vehicle air conditioning or as a windscreen wiper motor. In addition, a use in electric motors for power tools is possible. A use in slip-ring asynchronous motors and three-phase generators with high robustness and durability is conceivable.

Der Kommutator umfasst einen ankerseitigen Kollektor, der fest mit dem Anker der elektrischen Maschine gekoppelt ist, sowie mindestens eine am Kollektor anliegende, gehäusefeste Bürste, über die der Strom auf den Kollektor zur Bestromung von Ankerspulen übertragen wird. Mindestens ein stromübertragendes Bauteil des Kommutators ist als ein poröser Keramikkörper mit infiltriertem Metall ausgeführt. Der poröse Keramikkörper stellt einen Vorkörper (Preform) dar, der während des Herstellungsprozesses mit schmelzflüssigem Metall infiltriert wird, beispielsweise mittels Gasdruckinfiltration oder mittels Squeeze-Cast-Technologie. Das in dieser Weise ausgeführte stromübertragende Bauteil des Kommutators besteht somit aus einem Metall-Keramik-Verbundwerkstoff, welcher als Preform basierter Werkstoff (P-MMC) ausgeführt bzw. in dieser Weise hergestellt ist.The commutator comprises an armature-side collector which is fixedly coupled to the armature of the electric machine, and at least one brush fixed to the housing, via which the current is transmitted to the collector for energizing armature coils. At least one current-transmitting component of the commutator is designed as a porous ceramic body with infiltrated metal. The porous ceramic body is a preform that is infiltrated with molten metal during the manufacturing process, for example by gas pressure infiltration or squeeze-cast technology. The current-carrying component of the commutator embodied in this way thus consists of a metal-ceramic composite material which is designed as a preform-based material (P-MMC) or produced in this way.

Der Keramikanteil in dem Verbundwerkstoff sorgt für eine hohe Verschleiß- und Korrosionsbeständigkeit, außerdem wird eine hohe Temperaturbeständigkeit erreicht (bis zu 800 °C bei Verwendung von Cu als metallische Komponente). Die Keramikkomponente verringert die Reibung während der Relativbewegung zwischen Bürste und Kollektormantelfläche, so dass die Verschleißbeständigkeit erhöht ist.The ceramic content in the composite ensures high resistance to wear and corrosion, and high temperature resistance is achieved (up to 800 ° C when using Cu as a metallic component). The ceramic component reduces the friction during the relative movement between brush and collector shell surface, so that the wear resistance is increased.

Ein weiterer Vorteil besteht darin, dass auch größere Bauteile mit komplexen Geometrien vollständig und rissfrei mit dem Metall infiltrierbar sind. Dadurch können sowohl die Bürsten als auch der Kollektor mit der jeweils gewünschten Geometrie hergestellt werden.Another advantage is that even larger components with complex geometries are completely infiltrated with the metal without cracking. As a result, both the brushes and the collector can be produced with the respective desired geometry.

Bei dem erfindungsgemäßen Kommutator ist zumindest ein Kommutatorbauteil - eine oder mehrere Bürsten und/oder der Kollektor - aus dem Metall-Keramik-Verbundwerkstoff mit dem porösen Keramikkörper mit infiltriertem Metall hergestellt. In Betracht kommen sowohl Ausführungsvarianten, in denen nur die Bürsten oder nur der Kollektor oder sowohl die Bürsten als auch der Kollektor aus dem Metall-Keramik-Verbundwerkstoff hergestellt sind. Für den Fall, dass sowohl die Bürsten als auch der Kollektor aus dem Verbundwerkstoff bestehen, können sowohl gleiche Verbundwerkstoffe als auch unterschiedliche Verbundwerkstoffe für die Bürsten und den Kollektor eingesetzt werden bzw. gleiche oder auch verschiedene Mischungsverhältnisse von Keramik- zu Metallanteil eingesetzt werden.In the commutator according to the invention, at least one commutator component - one or more brushes and / or the collector - is made from the metal-ceramic composite material with the porous ceramic body with infiltrated metal. Both variant embodiments, in which only the brushes or only the collector or both the brushes and the collector are made of the metal-ceramic composite material, are possible. In the event that both the brush and the collector made of the composite material, both the same composite materials and different composite materials for the brush and the collector can be used or the same or different mixing ratios of ceramic to metal content can be used.

Als Keramikkomponente kommen Oxide, Nitride oder Carbide in Betracht, beispielsweise Al2O3, AIN, TiN, Si3N4, SiC oder siliziuminfiltriertes SiC. Als metallische Komponente werden bevorzugt hochleitfähige Werkstoffe eingesetzt, insbesondere Kupfer oder Kupferlegierungen, aber auch Silber, Gold, Aluminium, Eisen, Zinn sowie deren Legierungen. Darüber hinaus können bedarfsweise Schmier- und Abrasivstoffe zugegeben werden.Suitable ceramic components are oxides, nitrides or carbides, for example Al 2 O 3 , AlN, TiN, Si 3 N 4 , SiC or silicon-infiltrated SiC. As a metallic component preferably highly conductive materials are used, in particular copper or copper alloys, but also silver, gold, aluminum, iron, tin and their alloys. In addition, lubricants and abrasives may be added as needed.

Der als poröser Keramikkörper mit infiltriertem Metall ausgeführte Verbundwerkstoff besitzt aufgrund seiner dreidimensionalen Netzwerkstruktur der Gefügebestandteile neben der Verschleiß-, der Temperatur- und der Korrosionsbeständigkeit, die auf den Keramikanteil zurückgeht, auch eine hohe elektrische und thermische Leitfähigkeit. Durch Variation des Keramikanteils können spezifische elektrische Widerstände zwischen etwa 0.05 µΩm und 1015 Ωm erzeugt werden.Due to its three-dimensional network structure of the structural constituents, the composite material embodied as a porous ceramic body with infiltrated metal also has a high electrical and thermal conductivity in addition to the resistance to wear, temperature and corrosion that results from the ceramic component. By varying the ceramic content, specific electrical resistances between about 0.05 μΩm and 10 15 Ωm can be generated.

Es kann zweckmäßig sein, die Bürste mit mehreren Funktionsschichten herzustellen, die jeweils als Metall-Keramik-Verbundwerkstoff hergestellt sind, jedoch einen unterschiedlichen Metall- bzw. Keramikanteil aufweisen. Der Übergang zwischen diesen Funktionsschichten kann wahlweise diskret oder kontinuierlich sein. Die Bürste wird beispielsweise mit zwei Schichten mit unterschiedlichem Metallanteil ausgeführt, wobei die in Relativbewegungsrichtung vorn liegende Schicht als Leistungsschicht einen höheren Metallanteil aufweist und eine höhere Stromübertragungsrate aufweist als die in Relativbewegungsrichtung hinten liegende Schicht, die eine Kommutierungsschicht bildet. Der vergleichsweise höhere Keramikanteil in der Kommutierungsschicht ermöglicht durch einen hohen tangentialen Widerstand die Kommutierung und reduziert die an der ablaufenden Kante der Bürste entstehende Funkenbildung.It may be convenient to make the brush with multiple functional layers, each made as a metal-ceramic composite, but having a different metal or ceramic content. The transition between these functional layers can optionally be discrete or continuous be. The brush is designed, for example, with two layers with different metal content, the layer lying in the relative direction of movement having a higher metal content as the power layer and having a higher current transmission rate than the layer lying in the relative direction of movement forming a commutation layer. The comparatively higher proportion of ceramic in the commutation layer allows commutation by means of a high tangential resistance and reduces the formation of sparks on the running edge of the brush.

Für eine hohe Stromübertragungsrate ist es zweckmäßig, dass die Leistungsschicht, die einen höheren Metallanteil aufweist, im Verhältnis zur Kommutierungsschicht einen größeren Kontaktquerschnitt aufweist, insbesondere eine in Bewegungsrichtung gesehen größere Dicke, gegebenenfalls auch eine größere Breite quer zur Bewegungsrichtung. Die größere Kontaktfläche der Leistungsschicht erlaubt höhere Stromübertragungsraten.For a high current transfer rate, it is expedient that the power layer, which has a higher metal content, has a larger contact cross-section in relation to the commutation layer, in particular a greater thickness in the direction of movement, optionally also a greater width transversely to the direction of movement. The larger contact area of the power layer allows higher power transfer rates.

Zweckmäßigerweise ist auch der Kollektor aus einem Verbundwerkstoff mit einem verhältnismäßig hohen Metallanteil gefertigt, der eine hohe Stromübertragungsrate ermöglicht. Der Verbundwerkstoff, aus dem der Kollektor gefertigt ist, kann zumindest annähernd gleich aufgebaut sein wie der Verbundwerkstoff der Leistungsschicht in der Bürste, er weist aber zweckmäßigerweise einen höheren Metallanteil auf als die Kommutierungsschicht.Conveniently, the collector is made of a composite material with a relatively high metal content, which allows a high power transmission rate. The composite material from which the collector is made can be constructed at least approximately the same as the composite material of the power layer in the brush, but it expediently has a higher metal content than the commutation layer.

Als weiteres Ausführungsmerkmal kann der Kern des Kollektors als dichter keramischer Isolator dargestellt werden. Hierzu ist der keramische Vorkörper derart ausgeführt, dass die späteren Laufflächen des Kollektors aus einer frei wählbaren Zusammensetzung von Metall und Keramik bestehen. Dabei können axial entlang der Segmente des Kollektors unterschiedliche Mischungsverhältnisse Keramik- zu Metallanteil eingesetzt werden, um die elektrische Kontaktierung zur Ankerwicklung herzustellen.As a further embodiment feature, the core of the collector can be represented as a dense ceramic insulator. For this purpose, the ceramic precursor body is designed such that the later running surfaces of the collector consist of a freely selectable composition of metal and ceramic. In this case, different mixing ratios ceramic to metal portion can be used axially along the segments of the collector to produce the electrical contact with the armature winding.

Des Weiteren kann es zweckmäßig sein, einen herstellungsbedingten Umguss an der Bürste als Bürstenplatte zu verwenden, über die die elektrische Kontaktierung mithilfe eines starren oder flexiblen elektrischen Leiters (z.B. Litze) erfolgt. Der Umguss stellt eine die Oberfläche des Keramikkörpers zumindest teilweise bedeckende Schicht dar, die als Fußplatte zur Halterung und Kontaktierung der Schichten in der Bürste verwendet werden kann.Furthermore, it may be expedient to use a production-related encapsulation on the brush as a brush plate, via which the electrical contacting by means of a rigid or flexible electrical conductor (eg strand) takes place. The encapsulation represents a surface of the ceramic body at least partially covering layer, which can be used as a foot plate for holding and contacting the layers in the brush.

Weitere Vorteile und zweckmäßige Ausführungen sind den weiteren Ansprüchen, der Figurenbeschreibung und den Zeichnungen zu entnehmen. Es zeigen:

Fig. 1
eine perspektivische Darstellung eines Kommutators in einer elektrischen Maschine, bestehend aus einem ankerseitigen Kollektor und zwei diametral gegenüberliegenden, die Kollektormantelfläche kontaktierenden Bürsten,
Fig. 2
einen Schnitt durch eine Bürste, bestehend aus einer metallischen Bürstenplatte und zwei Schichten, die jeweils aus einem Metall-Keramik-Verbundwerkstoff bestehen und als poröser Keramikkörper mit infiltriertem Metall ausgeführt sind,
Fig. 3
ein Schnitt durch den Kollektor, dessen Segmente ebenfalls als poröser Keramikkörper mit infiltriertem Metall ausgeführt sind.
Further advantages and expedient embodiments can be taken from the further claims, the description of the figures and the drawings. Show it:
Fig. 1
3 a perspective view of a commutator in an electrical machine, consisting of an armature-side collector and two diametrically opposite brushes contacting the collector surface,
Fig. 2
a section through a brush, consisting of a metallic brush plate and two layers, each consisting of a metal-ceramic composite material and are designed as a porous ceramic body with infiltrated metal,
Fig. 3
a section through the collector, the segments are also designed as a porous ceramic body with infiltrated metal.

Der in Fig. 1 dargestellte Kommutator 1 wird zur Stromübertragung und Stromwendung in elektrischen Maschinen wie Elektromotoren bzw. Generatoren eingesetzt und umfasst einen zylindrischen Kollektor 2, der drehfest mit dem Anker der elektrischen Maschine verbunden ist, welcher drehbar in einem Stator gelagert ist, sowie Bürsten 3, die an der radial außen liegenden Mantelfläche des zylindrischen Kollektors 2 oder an der Scheibenlauffläche auf Kontakt anliegen und Strom auf den Kollektor 2 übertragen, welcher über eine Litze 4 in die Bürsten 3 geleitet wird. Der Kollektor 2 kann gegebenenfalls auch scheibenförmig ausgeführt sein. Andere Kontaktierungen, wie z.B. Metallbänder oder Andruckfedern sind ebenso möglich. In Fig. 1 weist der Kommutator 1 zwei diametral gegenüberliegende Bürsten 3 auf. Grundsätzlich in Betracht kommen aber auch Kommutatoren mit einer größeren Bürstenanzahl, beispielsweise vier oder sechs Bürsten.The in Fig. 1 shown commutator 1 is used for power transmission and current application in electrical machines such as electric motors or generators and comprises a cylindrical collector 2 which is rotatably connected to the armature of the electric machine, which is rotatably mounted in a stator, and brushes 3, which at the lie radially on the outer surface of the cylindrical collector 2 or on the disk running surface on contact and transmit electricity to the collector 2, which is passed through a strand 4 in the brush 3. If appropriate, the collector 2 can also be designed as a disc. Other contacts, such as metal bands or pressure springs are also possible. In Fig. 1 the commutator 1 has two diametrically opposite brushes 3. In principle, however, come into consideration also commutators with a larger number of brushes, for example, four or six brushes.

Der Kollektor 2 weist eine Vielzahl einzelner, in Umfangrichtung separierter Segmente 5 auf, die mit Ankerspulen elektrisch verbunden sind. Bei einer Drehbewegung des Ankers bzw. des Kollektors 2 in Drehrichtung 6 gleitet die Mantelfläche des Kollektors an der zugewandten Stirnfläche der Bürsten 3 entlang, zugleich erfolgt die Stromübertragung von den Bürsten 3 auf die Segmente 5 des Kollektors 2.The collector 2 has a plurality of individual, circumferentially separated segments 5, which are electrically connected to armature coils. During a rotary movement of the armature or the collector 2 in the direction of rotation 6, the lateral surface slides of the collector along the facing end face of the brushes 3, at the same time the power is transmitted from the brushes 3 to the segments 5 of the collector. 2

In Fig. 2 ist ein Schnitt durch eine Bürste 3 dargestellt. Die Stromzufuhr über die Litze 4 oder eine vergleichbare Kontaktierung erfolgt gegebenenfalls in eine Bürstenplatte 7, die eine Fußplatte darstellt und mit zwei Schichten 8 und 9 der Bürste verbunden ist, welche als Leistungsschicht 8 und Kommutierungsschicht 9 ausgebildet sind. Bezogen auf die Relativbewegung zwischen dem Kollektor und der Bürste liegt die Leistungsschicht 8 vorne und die Kommutierungsschicht 9 hinten, entsprechend ist mit 8a die zulaufende Kante (Vorderkante) der Bürste 3 und mit 9a die ablaufende Kante (Hinterkante) bezeichnet. Bei der Relativbewegung zwischen Bürste und Kollektor gelangt die Leistungsschicht 8 vor der Kommutierungsschicht 9 in Kontakt mit dem jeweils nächsten Segment 5 auf dem Kollektor 2. Die stirnseitige Kontaktfläche der Bürste 3, die auf Kontakt zur Mantelfläche des Kollektors liegt, ist mit Bezugszeichen 10 versehen.In Fig. 2 a section through a brush 3 is shown. The power supply via the strand 4 or a comparable contacting is optionally carried out in a brush plate 7, which is a base plate and is connected to two layers 8 and 9 of the brush, which are formed as a power layer 8 and commutation 9. Relative to the relative movement between the collector and the brush, the power layer 8 lies at the front and the commutation layer 9 at the rear, correspondingly 8a denotes the tapered edge (leading edge) of the brush 3 and 9a the trailing edge (trailing edge). During the relative movement between brush and collector, the power layer 8 in front of the commutation layer 9 comes into contact with the respective next segment 5 on the collector 2. The frontal contact surface of the brush 3, which is in contact with the lateral surface of the collector is provided with reference numeral 10.

Beide Schichten 8 und 9 der Bürste 3 bestehen aus einem Metall-Keramik-Verbundwerkstoff und sind als poröser Keramikkörper mit infiltriertem Metall ausgeführt (Preform-based Metal-Matrix-Composite - P-MMC). Es handelt sich hierbei um einen porösen, keramischen Vorkörper (Preform), der vorzugsweise druckunterstützt mittels Gasdruckinfiltration oder mittels Squeeze-CastTechnologie mit schmelzflüssigem Metall infiltriert wird. Zweckmäßigerweise besitzt die vorne liegende Leistungsschicht 8 einen größeren Kontaktquerschnitt als die hinten liegende Kommutierungsschicht 9, so dass im Bereich der Kontaktfläche 10 die Leistungsschicht 8 über eine größere Fläche die Mantelfläche des Kollektors berührt als die Kommutierungsschicht 9. Der größere Kontaktquerschnitt wird insbesondere durch eine größere Breite bzw. Dicke der Leistungsschicht 8 erzielt, gemessen in Relativbewegungsrichtung. Im Ausführungsbeispiel ist die Dicke der Leistungsschicht 8 etwa doppelt so groß wie die Dicke der Kommutierungsschicht 9.Both layers 8 and 9 of the brush 3 are made of a metal-ceramic composite material and are designed as a porous ceramic body with infiltrated metal (preform-based metal matrix composite - P-MMC). This is a porous, ceramic preform, which is preferably infiltrated by pressurized gas pressure infiltration or molten metal squeeze-cast technology. Expediently, the front power layer 8 has a larger contact cross section than the rear commutation layer 9, so that in the region of the contact surface 10, the power layer 8 touches the outer surface of the collector over a larger area than the commutation layer 9. The larger contact cross section is in particular by a larger width or thickness of the power layer 8 achieved, measured in the direction of relative movement. In the exemplary embodiment, the thickness of the power layer 8 is about twice as large as the thickness of the commutation layer 9.

Die Bürstenplatte 7, über die die elektrische Kontaktierung mittels der Litze 4 oder einer sonstigen Kontaktierung erfolgt, kann als Umguss ausgebildet sein, welcher während des Gießprozesses beim Einbringen des schmelzflüssigen Metalls in den porösen, keramischen Vorkörper entsteht. Der Umguss stellt eine Metallschicht auf der Keramikkörperaußenseite dar und besteht aus dem gleichen Material wie das in den Keramikkörper eingebrachte Metall. Als Keramikkomponente kommen Oxide, Nitride oder Carbide in Betracht, als Metall wird bevorzugt Kupfer oder eine Kupferlegierung verwendet. In Betracht kommen als metallische Komponente aber auch weitere hochleitfähige Metalle wie Silber, Gold, Aluminium, Eisen, Zinn sowie Legierungen hieraus.The brush plate 7, via which the electrical contacting takes place by means of the stranded wire 4 or another contacting, can be formed as an encapsulation, which is formed during the casting process during the introduction of the molten metal into the porous, ceramic preform. The infusion represents a metal layer on the ceramic body outside and consists of the same material as the introduced into the ceramic body metal. As the ceramic component, oxides, nitrides or carbides come into consideration, as the metal, copper or a copper alloy is preferably used. In consideration come as a metallic component but also other highly conductive metals such as silver, gold, aluminum, iron, tin and alloys thereof.

Die Leistungsschicht 8 und die Kommutierungsschicht 9 unterscheiden sich hinsichtlich ihres Keramik- bzw. Metallanteils. Die Leistungsschicht 8 weist einen höheren Metallanteil auf als die Kommutierungsschicht 9, was die elektrische Leitfähigkeit des Leistungsschicht 8 verbessert. Zugleich ist die Kommutierungsschicht 9 aufgrund des höheren Keramikanteils sehr verschleiß- und temperaturbeständig. Zudem ist die Funkenbildung im Bereich der ablaufenden Kante 9a aufgrund des höheren Keramikanteils reduziert.The power layer 8 and the commutation layer 9 differ with regard to their ceramic or metal content. The power layer 8 has a higher metal content than the commutation layer 9, which improves the electrical conductivity of the power layer 8. At the same time, the commutation layer 9 is very wear and temperature resistant due to the higher ceramic content. In addition, the sparking in the region of the trailing edge 9a is reduced due to the higher ceramic content.

In Fig. 3 ist der Kollektor 2 im Schnitt dargestellt. Die Segmente 5 auf der Außenseite des Kollektors 2, die in Umfangsrichtung jeweils voneinander separiert sind, sind ebenfalls aus einem Metall-Keramik-Verbundwerkstoff in Form eines porösen Keramikkörpers mit infiltriertem Metall (P-MMC) gefertigt.In Fig. 3 the collector 2 is shown in section. The segments 5 on the outside of the collector 2, which are each separated in the circumferential direction from each other, are also made of a metal-ceramic composite material in the form of a porous ceramic body with infiltrated metal (P-MMC).

Claims (13)

  1. Commutator for power transmission in an electric machine, comprising an armature-side collector (2) and at least one brush (3) bearing against the collector (2), characterized in that at least one power-transmitting component (2, 3) of the commutator (1) is embodied as a porous ceramic body with infiltrated metal preform-based metal-matrix composite.
  2. Commutator according to Claim 1, characterized in that the brush (3) is fabricated from the ceramic body with infiltrated metal.
  3. Commutator according to Claim 2, characterized in that a brush plate (7) of the brush (3) is formed by an encapsulation, which encapsulation is produced during the process of casting the metal into the ceramic body.
  4. Commutator according to one of Claims 1 to 3, characterized in that the collector (2) is embodied at least partially as a ceramic body with infiltrated metal.
  5. Commutator according to Claim 4, characterized in that the core (11) of the collector (2) is embodied as a ceramic insulator, which is the carrier of segments (5) which are formed as a ceramic body with infiltrated metal.
  6. Commutator according to one of Claims 1 to 5, characterized in that a power-transmitting component (2, 3) of the commutator (1) has at least two layers (8, 9) with a differing metal-ceramic component in the metal-ceramic composite material.
  7. Commutator according to Claims 2 and 6, characterized in that the brush (3) has two layers (8, 9) with a different proportion of metal, and the layer which is at the front - with respect to the relative movement between the collector (2) and brush (3) - has, as a power layer (8), a larger proportion of metal than the layer lying at the rear, which layer forms a commutation layer (9).
  8. Commutator according to Claim 7, characterized in that the power layer (8) has a larger contact cross section, with which the brush (3) is in contact with the collector (2), than the commutation layer (9).
  9. Commutator according to Claims 2, 4 and 7, characterized in that the proportion of metal in the collector (2) has at least approximately the same proportion of metal as the power layer (8) in the brush (3).
  10. Commutator according to Claims 2, 4 and 7, characterized in that the proportion of metal in the collector (2) is higher than the proportion of metal in the commutation layer (9) in the brush (3).
  11. Commutator according to one of Claims 1 to 10, characterized in that the ceramic component is composed of oxides, nitrides or carbides.
  12. Commutator according to one of Claims 1 to 11, characterized in that the metal component is composed of copper and/or a copper alloy.
  13. Electric machine having a commutator according to one of Claims 1 to 12.
EP10755172.3A 2009-09-23 2010-09-21 Commutator for power transmission in an electric machine Not-in-force EP2481131B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL10755172T PL2481131T3 (en) 2009-09-23 2010-09-21 Commutator for power transmission in an electric machine

Applications Claiming Priority (2)

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DE102009029687A DE102009029687A1 (en) 2009-09-23 2009-09-23 Commutator for power transmission in an electrical machine
PCT/EP2010/063840 WO2011036132A1 (en) 2009-09-23 2010-09-21 Commutator for power transmission in an electric machine

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EP2481131A1 EP2481131A1 (en) 2012-08-01
EP2481131B1 true EP2481131B1 (en) 2014-06-18

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US (1) US20120262025A1 (en)
EP (1) EP2481131B1 (en)
CN (1) CN102576968A (en)
BR (1) BR112012006525A2 (en)
DE (1) DE102009029687A1 (en)
IN (1) IN2012DN02317A (en)
PL (1) PL2481131T3 (en)
WO (1) WO2011036132A1 (en)

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EP3093355B1 (en) * 2015-05-13 2018-10-10 The Swatch Group Research and Development Ltd. Method for manufacturing a composite component of a timepiece or of a jewelry part, and composite component obtainable by such method
CN106207692B (en) * 2016-07-07 2018-11-20 合肥学院 A method of motor brush is prepared using rice husk
JP2018125980A (en) * 2017-02-01 2018-08-09 株式会社デンソー motor
DE102023102684A1 (en) 2023-02-03 2024-08-08 Schaeffler Technologies AG & Co. KG Power transmission unit of an electrical machine, method for operating and use of a power transmission unit

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US20120262025A1 (en) 2012-10-18
DE102009029687A1 (en) 2011-03-24
PL2481131T3 (en) 2014-11-28
WO2011036132A1 (en) 2011-03-31
BR112012006525A2 (en) 2016-04-26
CN102576968A (en) 2012-07-11
IN2012DN02317A (en) 2015-08-21
EP2481131A1 (en) 2012-08-01

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