US1898696A - Method of manufacturing commutator segments - Google Patents

Method of manufacturing commutator segments Download PDF

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Publication number
US1898696A
US1898696A US509577A US50957731A US1898696A US 1898696 A US1898696 A US 1898696A US 509577 A US509577 A US 509577A US 50957731 A US50957731 A US 50957731A US 1898696 A US1898696 A US 1898696A
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US
United States
Prior art keywords
segments
stock
commutator
die
segment
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
US509577A
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English (en)
Inventor
Charles E Sorensen
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.)
Ford Motor Co
Original Assignee
Ford Motor Co
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
Priority to BE384849D priority Critical patent/BE384849A/xx
Priority to NL32506D priority patent/NL32506C/xx
Application filed by Ford Motor Co filed Critical Ford Motor Co
Priority to US509577A priority patent/US1898696A/en
Priority to GB28012/31A priority patent/GB378253A/en
Priority to DEF72068D priority patent/DE600822C/de
Priority to FR730554D priority patent/FR730554A/fr
Application granted granted Critical
Publication of US1898696A publication Critical patent/US1898696A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • 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

Definitions

  • each segment invariably are composed of an annulus of copper segments, each of which is insulated from the rest and from the armature shaft to which the commutator is secured.
  • These commutator segments consist of strips of copper each having a ring sector cross section. The segments are alternated with mica 1nsulating strips to form an annulus, the periphery of which is machined to a true circumference for the current carrying brushes to operate upon. That edge of each segment which goes to form the inside of the commutator ring is provided with a dovetailed portion or similar device for retaining the segment in place.
  • a lug extends radially from the inside end of each commutator segment to which the armature windings are secured.
  • radial slots are machined in these lugs in which two or more terminal wires from the armature windings are fastened.
  • the armature windings of such starting motors are composed of copper bars of rectangular section, approximately inch thick and 1 5 inch wide, so that it will be seen that these lugs must extend a considerable height above the periphery or brush ring surface of the commutator in order that the slots receive these bars. It will further be seen that due to the great height required for these lugs, the thickness of their outer ends is two or more times that of the bottom or dovetailed portion of the Serial No. 509,577.
  • the former methods used to manufacture these segments has been to either machine the segments out of solid copper bar stock, which is a very costly and slow process, or else to roll tapered copper stock to a width equivalent to the distance between the bottom of the segment retaining dovetail and the top of the terminal lug. Such tapered stock is then fed through punch presses which stamp out the'required combined segments and terminal lugs. It will be seen that by this method the major portion of the copper stock is scrapped during the removal of the thick portion of the material to form the terminal lug. As this scrapped portion of the stock is at least twice as thick as the inside edge of the stock and extends the height of the lug and about ths of the length of the seg ment, the loss of material from this cause is very high.
  • the segments are formed from tapered stock having a width only as great as the depth of the segment'from the brush surface to the bottom of the retaining dovetail which is only about half that required with the former method.
  • the material for the lug is taken from the stock itself which is cold-headed in suitable dies to thereby flow the metal outwardly, forming the terminal lug. An insignificant amount of stock is scrapped by this process which reduces the cost of such segments to only a fraction of their former cost.
  • a further object of my invention is to provide a segment substantially twice as thick as could be formed by the ordinary stamping method. Due to the relatively small number of segments required in starting motors and generators and the relatively large terminal bars which need to be secured to the lugs of each segment, the angular thickness of each segment is necessarily large. It is not commercially possible to stamp out such segments from a single piece of thick stock because the thickness of the lug is greater than its width and the metal, when such attempt is made, distorts or spreads out producing a segment having curved side walls. In order to overcome such disadvantage, these segments have been built up from two stampings placed side by side, each of which is punched from metal of only. half the thicknessaof the segment. With my improved method one piece segments of any desired thickness may be made to form a commutator having only half the number of parts formerly necessary. The assembly cost of commutators built according to my improved method is materially lessened, due to the reduced number of parts therein.
  • Still a further object of my invention is to provide a method of forming commutator segments whereby the metal thereof will be niaterially hardened incidental to the forming operations, to thus form a harder and consequently longer lived commutator; lhe copper stock used to form the conventional commutator segments must be rolled to size and the subsequent punching of the segments therefrom leaves the copper stock in its original soft condition.
  • I deform the structure of the segment sllil'iciently to produce a hard metal structure.
  • the hard structure formed by such working is undesirable and subsequent annealing must be provided for, however, in this instance the hard structure is desirable inasmuch as it produces a segment having a much longer life than could formerly be provided.
  • a commutator built up from such segments "forming a harder brush surface will, therefore, be an advantage.
  • Still a further object of this invention is to provide a method whereby two segments are formed in a die at one operation, which operation can be carried on in an automatic machine to thereby reduce the cost of these segments to an amount only slightly more than the actual cost of the copper used therein.
  • Figure 1 shows a perspective view of a commutator segment produced according to my improved method.
  • Figure 2 shows a perspective view of a pair of the segments, shown in Figure 1, illustrating the manner in which they are formed in airs.
  • p Figure 3 shows a length of copper stock used to form the pair of segments, shown in Figure 2.
  • Figure 4 shows a perspective view of the stock used to form the sections, shown in Figure '3.
  • Figure 5 shows a perspective view of a commutator constructed from segments formed according to my improved method.
  • F igurefi shows a fragmentary central sectional view through a starting motor commutator illustrating the means whereby the segments are retained in position.
  • Figure 7 shows a side view of one of the dies used to form the segments.
  • Figure 8 shows a plan view of a set of dies. consisting of a heading die, cut-off die and one-half of the holding die, the heading die being withdrawn to illustrate the p ⁇ 'lll()ll of the stock therein prior to the heading operation.
  • Figure 9 shows a plan view of the dies shown in Figure 8, the heading die being inserted to illustrate its cold-heading action in forming the terminal lugs of the segn'mnt.
  • Figure 10 shows a perspective view of the cut-off dies shown in Figure 8.
  • Figure 11 shows a diagrammatic view of the complete set of dies illustrating the positions wherein the stock is fed into the dies.
  • Figure 12 shows a diagrammatic view illustrating the positions wherein the cut-off die has been lowered to shear a length of the stock.
  • Figure 13 shows a diagrammatic view of the several dies with the heading die forced home to form the terminal lugs on the scgments.
  • Figure 14 shows a diagrammatic view of the dies in their separated positions, showing how the incoming stock ejects the headed pair of segments from the dies, and
  • Figure 15 shows a plan view of the ordinary commutator, illustrating the construction wherein two stampings were required to form a single segment of the required thickness and angularity.
  • FIG. 1 have used the reference numeral 10 to indicate an armature shaft usually associated with automobile starting motors and generators.
  • I have provided a sleeve 11 upon which is mounted a commutator 12.
  • This commutator is built up from an annulus of copper commutator segments 13 having tapered cross sections as required from the size of the commutator and the number of segments therein. The inner edges of these segments are dovetailed, as at 14:, so that a pair of clamping collars 15, secured on the ends of the sleeve 11, may co-act with these dovetails to retain the ring of segments in place.
  • Suitable insulation 16 of mica or other material is placed between the collars 15 and the dovetail and also between the indivdual segments to thereby insulate each segment from the remaining segments and from the arma- Pressed on one end of this shaft ture shaft.
  • Terminal lugs 17 extend radiing equivalent to the total height of two of ally from the inner ends of the segments 13, the segments and lugs. The proportion of each of these lugs having a radial slot 18 this die is governed by the dimensions of the machined therein to receive the ends of a required commutator segment and may be 5 pair of conductor bars 19 from the armature varied to the various sizes of commutator 7 windings. These windings consist of relasegments.
  • the die block 2-l may be built tively heavycopper bars which are pressed up from two halves, if desired, so that the into the slots and then soldered in place to slots therein may be conveniently machined form a. permanent electrical connection with and the two halves secured together.
  • the sleeve 11 is then transversely to the slot which cut-01f die 8 inserted and the collars 15, with the necesis provided with a slot 29 extending theresary insulation rings, are forced into the through of the same cross section as the slot grooves formed by the dovetailed portions 25 with which it is normally aligned.
  • the and the ends of the sleeve flattened down to die 28 is provided with an integral lug 30 thereby prevent the withdrawal of the col projecting into a complementary shaped 85 lars.
  • the commutator is then removed from groove 31 in the die block which lug and the die and the periphery given a light finishgroove extend through the center of the ing cut to thereby provide a smooth surface slot and projects perpcndicularly therefor the motor brushes to operate upon.
  • the contour of the lug and groove slots 18 are then machined in the segments 31 is determined by the recess 32 as and the device assembled on the armature shown in Figure 2, and retuired to form shaft.
  • the die block to roll the copper material from which the 24 is held in a heading machine having a pair 30 commutator segments are to be made in the of slides reciprocating at right angles to each form of a strip 20 having a width just twice other and the heading die 27 is secured to one that of the depth of the segment between of these slides while the cut-off die 28 is se-' its brush face and the bottom of the dovetail cured to the other.
  • This strip is flat on one side with its Referring to Figures 11 through 14,1 have 35 center portion on the opposite side considerprovided a pair of feeding rollers 33 which ably thinner than the edges thereof, these are driven and timed to intermittently force dimensions being governed by the taper of the stock 20 into the slot 29 in the cut-oft die. the segments to be formed. It will be noted The dies are located in the machine with the that with such stock two segments are formed slots 25 and 29 aligned when the machine is 40 sideby side; however, if desired, stock half at the end of its stroke at which time the 106 this width may be used thereby forming only feeding rollers 33 then push the stock through one segment at a time.
  • the die method is to first cut off a length of the stock, 28 is then reciprocated downwardly which- 45 as shown at 21 in Figure 3, and While holdshears off the length 21 from the stock 20. 110
  • the leading end is WVhile the die 28 is still in this lowered posispread out to form a blank 22, as shown in tion, the heading die 27 is driven forwardly Figure 2. That portion of the blank 22 outinto the slot 26 thereby deforming the length lined by the dotted lines 23 is then punched of stock 21 therein by forcing the metal into 50 out and the blank sheared along its center the inner end of the slot 26, as illustrated in line to form a pair of segments, as illustrated Figure 13. The die 27 is not driven to the in Figure 1.
  • this slot being of a cross H TThe'die2"kis'thenmglginto its startsection equivalent to the cross section of ing position wherebv the portion of the stock the stock 20.
  • the slot 25 is enlarged for within the die is accurately sized for len th about half the distance through the die block, and the foregoing operation repeated.
  • the ordinary commutator is shown.
  • the terminal lugs which extend from each segment may be seen to have a relatively great angular width.
  • the thickness of the stock was limited so that each of such connnntator segments had to be made from two stampings placed side by side.
  • the terminal lugs can readily he formed having a greater angular width than their thickness so that only one member is required for each segment. This feature reduces the assembly costand forms a better commutator.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Manufacture Of Motors, Generators (AREA)
US509577A 1931-01-19 1931-01-19 Method of manufacturing commutator segments Expired - Lifetime US1898696A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
BE384849D BE384849A (en(2012)) 1931-01-19
NL32506D NL32506C (en(2012)) 1931-01-19
US509577A US1898696A (en) 1931-01-19 1931-01-19 Method of manufacturing commutator segments
GB28012/31A GB378253A (en) 1931-01-19 1931-10-08 Improvements in a method of manufacturing commutator segments
DEF72068D DE600822C (de) 1931-01-19 1931-10-22 Herstellung von Kommutatorsegmenten durch Ausschneiden aus einem fortlaufenden Doppelstreifen Kupfer
FR730554D FR730554A (fr) 1931-01-19 1931-10-23 Procédé et appareil pour la fabrication des lames de collecteur

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US509577A US1898696A (en) 1931-01-19 1931-01-19 Method of manufacturing commutator segments

Publications (1)

Publication Number Publication Date
US1898696A true US1898696A (en) 1933-02-21

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Application Number Title Priority Date Filing Date
US509577A Expired - Lifetime US1898696A (en) 1931-01-19 1931-01-19 Method of manufacturing commutator segments

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US (1) US1898696A (en(2012))
BE (1) BE384849A (en(2012))
DE (1) DE600822C (en(2012))
FR (1) FR730554A (en(2012))
GB (1) GB378253A (en(2012))
NL (1) NL32506C (en(2012))

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2519626A (en) * 1945-05-02 1950-08-22 Paul R Blair Commutator bar and method of making same
US2558423A (en) * 1948-09-08 1951-06-26 Dobrosky Michael Spoke ornament for bicycle wheels
US2677874A (en) * 1947-11-29 1954-05-11 Gen Motors Corp Manufacture of commutators
US2694952A (en) * 1954-11-23 Manufacture of commutator bars
US2795841A (en) * 1952-10-27 1957-06-18 Lincoln Electric Co Method of manufacturing commutators
US3459983A (en) * 1965-02-18 1969-08-05 Lucas Industries Ltd Commutator segments for dynamoelectric machines and coil end connectors
US3720998A (en) * 1970-05-06 1973-03-20 Asea Ab Method of manufacturing commutator segments of compound material
CN103567266A (zh) * 2013-11-12 2014-02-12 上海昭程整流子科技有限公司 自动弯钩装置
CN108933373A (zh) * 2018-07-23 2018-12-04 江苏瑞翔电器有限公司 一种换向器用换向片连续式加工设备

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2718012A (en) * 1952-10-11 1955-09-20 Howe Elra Francis Self-contained toilet unit and pump usable therewith
DE1072310B (en(2012)) * 1956-09-08
DE1241901B (de) * 1963-08-24 1967-06-08 Kb Awiazionnij I Verfahren zur Herstellung von Kollektorlamellen und Vorrichtung zur Durchfuehrung dieses Verfahrens
BE682136A (en(2012)) * 1965-07-12 1966-11-14
DE8815711U1 (de) * 1988-12-19 1990-04-12 Robert Bosch Gmbh, 7000 Stuttgart Kommutatorlamelle

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2694952A (en) * 1954-11-23 Manufacture of commutator bars
US2519626A (en) * 1945-05-02 1950-08-22 Paul R Blair Commutator bar and method of making same
US2677874A (en) * 1947-11-29 1954-05-11 Gen Motors Corp Manufacture of commutators
US2558423A (en) * 1948-09-08 1951-06-26 Dobrosky Michael Spoke ornament for bicycle wheels
US2795841A (en) * 1952-10-27 1957-06-18 Lincoln Electric Co Method of manufacturing commutators
US3459983A (en) * 1965-02-18 1969-08-05 Lucas Industries Ltd Commutator segments for dynamoelectric machines and coil end connectors
US3720998A (en) * 1970-05-06 1973-03-20 Asea Ab Method of manufacturing commutator segments of compound material
CN103567266A (zh) * 2013-11-12 2014-02-12 上海昭程整流子科技有限公司 自动弯钩装置
CN103567266B (zh) * 2013-11-12 2015-11-04 上海昭程整流子科技有限公司 自动弯钩装置
CN108933373A (zh) * 2018-07-23 2018-12-04 江苏瑞翔电器有限公司 一种换向器用换向片连续式加工设备
CN108933373B (zh) * 2018-07-23 2023-09-01 江苏瑞翔电器有限公司 一种换向器用换向片连续式加工设备

Also Published As

Publication number Publication date
FR730554A (fr) 1932-08-18
GB378253A (en) 1932-08-11
NL32506C (en(2012))
BE384849A (en(2012))
DE600822C (de) 1934-08-01

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