US3708872A - Method of producing a molded commutator - Google Patents

Method of producing a molded commutator Download PDF

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Publication number
US3708872A
US3708872A US00043788A US3708872DA US3708872A US 3708872 A US3708872 A US 3708872A US 00043788 A US00043788 A US 00043788A US 3708872D A US3708872D A US 3708872DA US 3708872 A US3708872 A US 3708872A
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United States
Prior art keywords
commutator
dividing grooves
cylindrical body
molded
producing
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
US00043788A
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English (en)
Inventor
T Honshima
Y Ohuchi
H Kanamaru
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Hitachi Ltd
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Hitachi Ltd
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Publication date
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Publication of US3708872A publication Critical patent/US3708872A/en
Anticipated expiration legal-status Critical
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06—Manufacture of commutators
    • H01R43/08—Manufacture of commutators in which segments are not separated until after assembly
    • 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
    • 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

  • ABSTRACT A flanged cylindrical body formed by suitable means is disposed in a cavity die assembly and then a' plurality of commutator bar dividing grooves and commutator riser dividing grooves are formed in the flanged cylindrical body rectilinarly by a suitable stamping operation, without resorting to mechanical cutting at all, while taking the flow balance of the material into consideration, thereby to form a shrink ring for the commutator. Thereafter, a molding material is charged into the thus formed shrink ring for the commutator and the material connecting the commutator bars and commutator rises is removed, whereby a molded commutator is produced.
  • the conventional method as described above not only provides the danger of shorting between the commutator bars through the chip, but also requires a high skill in machining the commutator bar dividing grooves and the commutator riser dividing grooves which must be in alignment with each other, as these grooves cannot be machined concurrently, and hence this is not adapted for the mass production of commutators.
  • a further disadvantage of the conventional method which cannot be overlooked, is that a large quantity of copper material is wastefully consumed because in the formation of the commutator bars independently of each other, the portion connecting the commutator bars must be cut away by a lathe after charging the molding material.
  • An object of the present invention is to provide a shrink ring for a commutator having commutator bar dividing grooves and commutator riser dividing grooves formed therein, from a relatively small quantity of material and in a relatively small number of operational steps by a cold forging method, without involving a mechanical cutting operation.
  • Another object of the invention is to provide a method by which a groove to be formed in each side surface of a commutator bar for the purpose of producing a stronger bond with a molding material can be formed concurrently with the formation of a shrink ring of commutator, without resorting to a mechanical cutting operation.
  • FIG. 1 is a sectional view illustrating the step of working the starting material.
  • FIG. 2 is a sectional view illustrating the step forming an annular body.
  • FIGS. 3 and 4 are sectional views illustrating the step of forming a flanged cylindrical body.
  • FIG. 5 is a sectional view illustratingthe first groove cutting step using a stamping die.
  • FIG. 6 is a sectional view taken on the line VIVI of FIG. 5.
  • FIG. 7 is a sectional view illustrating the dividing groove forming step.
  • FIG. 8 is a sectional view taken on the line VIII-VIII of FIG. 7.
  • FIG. 9 is an enlarged fragmentary sectional view showing the essential portion of FIG. 8.
  • FIG. 10 is a sectional view taken on the line X-X of FIG. 8.
  • FIG. 1 1 is an enlarged fragmentary sectional view showing the essential portion of FIG. 10.
  • FIG. 12 is a perspective view of a shrink ring for a commutator.
  • FIG. 13 is an enlarged fragmentary side view of FIG. 12.
  • FIG. 14 is a sectional view illustrating the molding material charging step.
  • FIG. 15 is a perspective view of the commutator obtained from the step of FIG. 14.
  • FIG. 16 is a sectional view illustrating the step of forming coil mounting grooves in the commutator risers.
  • FIG. 17 is a perspective view of the commutator obtained from the step of FIG. 16.
  • FIG. 18 is a perspective view of the complete molded commutator.
  • the present invention provides a method of producing a molded commutator in which, as shown in FIG. 18, commutator bars If each having an armature coil mounting notch 33 formed in the riser portion are arranged in concentrical relation and molded by a molding material.
  • a copper rod is first of all cut into a piece of suitable length to provide a starting material 1.
  • This starting material 1 is disposed in a cavity die assembly 2, 3 and pressed by a stamping die 4 to obtain a disc-shaped body 10.
  • the disc-shaped body thus obtained is then disposed in a cavity die assembly 5, 6 in the second step (FIG. 2) and deformed by a punch 7 into the shape of a cup having a bottom wall 1b and a cylindrical side wall 10.
  • the cup-shaped body is transferred to apparatus for performing the third step (FIG. 3), wherein it is mounted on the upper surface of a cavity die assembly 8, 9, l0 and the material of the bottom wall 1b thereof is caused to flow radially outwardly by a punch 13 to form an annular flange 1d, while confining the outer diameter of the cylindrical side wall 10 by means of a core die 11 and the height of the same by a core die 12.
  • the body obtained from the third step is transferred onto a die 14 of FIG. 4 and the bottom wall lb is punched by a punch 16, while confining the outer peripheral surface thereof by a core die 15, to form a flanged cylindrical body 17.
  • grooves 1e are formed in the inner peripheral edge portion at the same pitch as the commutator bar dividing grooves to be formed in the next step, as shown in FIG. 6.
  • the next step is the one of forming grooves 18 and 19 which will divide the commutator bars If and the commutator risers 1g.
  • the flanged cylindrical body 17 is inserted in an inverted position into a cavity die 21 having a die 20 provided therebeneath, and the grooves are formed by pressing by the cooperation of a punch 22 and a stamping die 23, while defining the inner diameter of the body by said punch 22.
  • the punch 22 and the stamping die 23 are respectively provided with circumferentially equally spaced working teeth 22a, 23a at the lower portions thereof. These working teeth are formed in opposed relation to grooves 21a, 21b formed in the core die 21 respectively with a slight space therebetween, and are provided with projecting teeth 23c for forming grooves 18a in the side surfaces of the commutator bars concurrently.
  • the working teeth 22a and the grooves 20a are in close contact with each other. In this step, therefore, the flanged cylindrical body 17 obtained in the fourth step (FIG.
  • a bush 30 is inserted into the hollow of the commutator shrink ring, obtained in the preceding step, by way of a core pin 29, while holding the outer peripheral surface of the ring by a cavity die assembly 24, 25, 26, 27, 28, and then a molding material 31 is charged with pressure into the gaps formed between said bush and the shrink ring, whereby a molded commutator ring as shown in FIG. is obtained.
  • armature coil mounting notches 33 are formed by punching tool 34 while holding immovably the peripheral wall of the ring by a die 32.
  • the material connecting the adjacent commutator bars lfand adjacent risers 1g with each other is cut away by means of a lathe, whereby a complete molded commutator is obtained.
  • the fifth step (FIG. 5) is provided for the purpose of precluding the formation of a burr in the gap at the joint of the individual pieces of the stamping die assembly. Therefore, this step can be eliminated if it is technically possible to form the stamping die as a unitary piece.
  • the flanged cylindrical body obtained from the fourth step in not necessarily produced by the process described herein but can be produced from a pipe or directly by die casting without going through a plurality of steps.
  • the work is performed while holding the end faces of the commutator bars by the die and, therefore, a burr will not be formed at the end faces by stamping.
  • the holding grooves 18a are formed in the side surfaces of the commutator bars concurrently when the commutator bar dividing grooves 18 are formed and, therefore, an additional step of forming such grooves can be eliminated.
  • a molded commutator can be produced in a rational manner with an excellent productivity in a relatively less number of operational steps.
  • a method of producing a molded commutator having a plurality of commutator bars and a plurality of commutator risers comprising the steps of:

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
US00043788A 1969-06-13 1970-06-05 Method of producing a molded commutator Expired - Lifetime US3708872A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP44047175A JPS4837761B1 (enrdf_load_stackoverflow) 1969-06-13 1969-06-13

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US3708872A true US3708872A (en) 1973-01-09

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US00043788A Expired - Lifetime US3708872A (en) 1969-06-13 1970-06-05 Method of producing a molded commutator

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JP (1) JPS4837761B1 (enrdf_load_stackoverflow)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2412184A1 (fr) * 1977-12-15 1979-07-13 Paris & Du Rhone Perfectionnements aux collecteurs de machines tournantes dynamoelectriques et procede pour leur mise en oeuvre
US4180900A (en) * 1977-03-04 1980-01-01 Itt Industries, Inc. Apparatus for making a commutator for an electric motor
US4247795A (en) * 1976-02-20 1981-01-27 Lucas Industries, Limited Commutator
US4370799A (en) * 1980-03-24 1983-02-01 Kolektor P.C. Method for manufacturing unfinished parts for pressed material commutators
US4611391A (en) * 1982-11-19 1986-09-16 Robert Bosch Gmbh Commutator ring manufacturing method and apparatus
US4667394A (en) * 1982-11-19 1987-05-26 Robert Bosch Gmbh Method of making a commutator ring having segments
US5729070A (en) * 1994-03-31 1998-03-17 Sayama Precision Industries Co., Ltd. Commutator assembly for small motor, method for producing the same, and commutator piece joint body for the small motor
WO2010009959A3 (de) * 2008-07-25 2010-06-03 Robert Bosch Gmbh Kommutator für eine elektrische maschine sowie system

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0329562U (enrdf_load_stackoverflow) * 1989-07-31 1991-03-25
JP2011050169A (ja) * 2009-08-27 2011-03-10 Mitsuba Corp コンミテータの製造方法およびコンミテータ

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3251120A (en) * 1960-04-30 1966-05-17 Bosch Gmbh Robert Method of making a commutator
US3407491A (en) * 1965-10-23 1968-10-29 Gen Motors Corp Molded commutator
US3478421A (en) * 1966-07-20 1969-11-18 Lucas Industries Ltd Method of manufacturing commutators
US3482307A (en) * 1966-03-30 1969-12-09 Nippon Denso Co Method for producing commutators for miniature electric machines

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3251120A (en) * 1960-04-30 1966-05-17 Bosch Gmbh Robert Method of making a commutator
US3407491A (en) * 1965-10-23 1968-10-29 Gen Motors Corp Molded commutator
US3482307A (en) * 1966-03-30 1969-12-09 Nippon Denso Co Method for producing commutators for miniature electric machines
US3478421A (en) * 1966-07-20 1969-11-18 Lucas Industries Ltd Method of manufacturing commutators

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4247795A (en) * 1976-02-20 1981-01-27 Lucas Industries, Limited Commutator
US4328440A (en) * 1976-02-20 1982-05-04 Lucas Industries Limited Commutator
US4180900A (en) * 1977-03-04 1980-01-01 Itt Industries, Inc. Apparatus for making a commutator for an electric motor
US4290191A (en) * 1977-03-04 1981-09-22 Itt Industries, Inc. Method for making a commutator for an electric motor
FR2412184A1 (fr) * 1977-12-15 1979-07-13 Paris & Du Rhone Perfectionnements aux collecteurs de machines tournantes dynamoelectriques et procede pour leur mise en oeuvre
US4370799A (en) * 1980-03-24 1983-02-01 Kolektor P.C. Method for manufacturing unfinished parts for pressed material commutators
US4611391A (en) * 1982-11-19 1986-09-16 Robert Bosch Gmbh Commutator ring manufacturing method and apparatus
US4667394A (en) * 1982-11-19 1987-05-26 Robert Bosch Gmbh Method of making a commutator ring having segments
US5729070A (en) * 1994-03-31 1998-03-17 Sayama Precision Industries Co., Ltd. Commutator assembly for small motor, method for producing the same, and commutator piece joint body for the small motor
WO2010009959A3 (de) * 2008-07-25 2010-06-03 Robert Bosch Gmbh Kommutator für eine elektrische maschine sowie system

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Publication number Publication date
JPS4837761B1 (enrdf_load_stackoverflow) 1973-11-13

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