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EP0127801A1 - Commutator for an electric machine and method of making it - Google Patents

Commutator for an electric machine and method of making it Download PDF

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Publication number
EP0127801A1
EP0127801A1 EP84105347A EP84105347A EP0127801A1 EP 0127801 A1 EP0127801 A1 EP 0127801A1 EP 84105347 A EP84105347 A EP 84105347A EP 84105347 A EP84105347 A EP 84105347A EP 0127801 A1 EP0127801 A1 EP 0127801A1
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EP
European Patent Office
Prior art keywords
ceramic body
eutectic
segments
copper
collector
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.)
Granted
Application number
EP84105347A
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German (de)
French (fr)
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EP0127801B1 (en
Inventor
Jens Dr. Ing. Gobrecht
Claus Dr. Schüler
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.)
ABB AG Germany
Original Assignee
BBC Brown Boveri AG Switzerland
ABB Asea Brown Boveri Ltd
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Application filed by BBC Brown Boveri AG Switzerland, ABB Asea Brown Boveri Ltd filed Critical BBC Brown Boveri AG Switzerland
Priority to AT84105347T priority Critical patent/ATE23080T1/en
Publication of EP0127801A1 publication Critical patent/EP0127801A1/en
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Classifications

    • 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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S228/00—Metal fusion bonding
    • Y10S228/903—Metal to nonmetal
    • 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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S29/00—Metal working
    • Y10S29/048—Welding with other step
    • 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

  • the invention relates to a collector according to the preamble of claim 1 and a method for its production according to the preamble of claim 6.
  • Collectors for electrical machines consist of radially arranged, centrally symmetrical metal segments (copper lamellas) forming a cylindrical body of rotation, which are insulated from each other and held together by rings.
  • the segments are dovetail-shaped and are held together by press rings exerting axial pressure with the interposition of mica insulation.
  • the segments of the shrink ring collector are held together by shrink rings, which exert radial forces on the entire plate pack. The latter as a whole must be insulated from neighboring metal parts in all cases. Mica and mica products are mainly used for this purpose.
  • collectors are very high mechanical and exposed to thermal stress. Therefore, they are mostly designed as so-called vault pressure collectors. This means that, even at the highest peripheral speeds (spin speed), adjacent lamellas must not gap, but must still be in contact with each other under mutual tangential pressure.
  • the calculation and design of these conventional collectors therefore requires great care and experience.
  • Their production as well as their entire technology (heat treatment, forming) represents practically a craft art, to which very high demands are made. This is related to the tendency to instability of the mica isolation.
  • the mica products have no tensile strength perpendicular to their layer surface and in parallel only a negligible low shear strength. They may therefore only be subjected to pressure perpendicular to the layer surface.
  • the individual mica platelets have a tendency to move against each other, which can be caused by uneven heating (starting from a standstill in rail engines) or mechanical overload. As a result, individual slats can be moved irreversibly and lead to malfunctions.
  • the invention is based on the object of specifying a collector for an electrical machine which, as a whole, behaves as much as possible as a monolithic body, does not contain any insulating intermediate layers which tend to mechanical instabilities and is as simple as possible in its construction.
  • the corresponding manufacturing process should be reproducible with simple means and should not place high demands on manual skills.
  • a collector with a smooth ceramic body is shown in longitudinal section.
  • 1 is a rotationally symmetrical sintered ceramic body (Al 2 O 3 ) with a smooth cylindrical surface.
  • 2 represents a metallic segment (copper lamella) with a rectangular cross section and a flat inner boundary surface.
  • the connection between 1 and 2 is ensured by an eutectic intermediate layer 3 (Cu / Cu 2 O eutectic).
  • the inner boundary surface of the ceramic body 1 can be designed differently and also differ from the cylindrical shape. In particular, for constructional reasons, attachments, recesses, etc. can be provided on the machine shaft.
  • FIG. 2 shows the cross section through the collector according to FIG. 1.
  • the reference symbols correspond exactly to those in the first figure.
  • the thickness of the eutectic intermediate layer 3 is drawn in a greatly exaggerated manner in order to emphasize its importance. In reality, this thickness ranges from about 5 to 50 11 .
  • Fig. 3 shows a collector with a used ceramic body 4 is a groove running parallel to the axis of the ceramic body 1 in the same, 5 the corresponding web.
  • the segments 2 are embedded in the grooves 5 with virtually no play.
  • the remaining reference numerals correspond to those in FIG. 2.
  • the end portions of the segments 2 each have a radial height that decreases towards the end. 6 is a beveled, 7 a rounded end of the segment 2, while in the latter case the end of the segment 2 has a relief notch 8.
  • a dense ceramic body 1 was produced from technically pure aluminum oxide by sintering.
  • the ceramic body 1 was rotationally symmetrical and generally had approximately a hollow cylindrical shape with the following dimensions and properties:
  • a massive electrolytic copper plate of 176 x 75 x 5 mm was used to manufacture segments 2. On one side, parallel grooves of 0.6 mm width, 3.5 mm depth and 4.75 mm center distance were milled into the copper plate. Then the milled copper plate was used for relaxation and softening of the material for 20 min. annealed at a temperature of 800 o C under protective gas (90% Ar / 10% H 2 ). The cooled copper plate was coated on the flat, not milled side with masking lacquer and for 20 minutes for surface oxidation. immersed in a chemical bath of the following composition:
  • the copper plate was then 2 x 10 min. rinsed in distilled water and the topcoat on the outside removed.
  • the copper plate was now bent around the ceramic body 1, with the grooved side facing inwards, so that a complete hollow cylindrical body with an outer diameter of 66 mm was formed. In this position, the bent copper body was pressed radially against the ceramic body 1 by wrapping molybdenum wire with a thickness of 0.2 mm using a tensile stress.
  • the copper body is attached to the ceramic body 1 by a holding device made of a nickel superalloy (e.g. IN 100) with the interposition of a thin molybdenum sheet (approx. 0.05 mm thick) in order to avoid an undesired metallurgical connection between the workpiece and the tool pressed.
  • a holding device made of a nickel superalloy (e.g. IN 100) with the interposition of a thin molybdenum sheet (approx. 0.05 mm thick) in order to avoid an undesired metallurgical connection between the workpiece and the tool pressed.
  • the workpiece was removed from the holder and the hollow cylindrical copper body was turned to an outer diameter of 63 mm until the grooves broke.
  • the exposed segments 2 created by this method step no longer have any connection with one another.
  • a ceramic body 1 provided on its outer periphery with grooves 4 and webs 5 was produced from aluminum oxide by extrusion and sintering. Its properties corresponded to those of Example I. The dimensions were:
  • the ceramic body 1 was pretreated according to Example I.
  • the segments 2 made of electrolytic copper had a rectangular cross section and had the following dimensions:
  • the segments 2 were surface oxidized in a chemical bath as indicated in Example I. Then they were pressed radially into the grooves 4 of the ceramic body and held in place by means of a heat-resistant clamping device.
  • the heat treatment for the purpose of producing the eutectic intermediate layer 3 was carried out exactly according to the example game I.
  • the temperature for heating the workpiece parts to be connected may be 1075 i 7 ° C.
  • the ends of the segments 2 are designed with a decreasing radial height in order to reduce residual stresses and to avoid stress peaks at the points of discontinuity.
  • the beveled (6) or rounded (7) ends of the segments 2 shown in FIGS. 4 a to c and the relief notch 8 are used for this purpose.
  • the ceramic body 1 can consist of zirconium oxide or of aluminum oxide doped with zirconium oxide.
  • the segments 2 can also consist of a material other than copper or a copper alloy and can only be copper-plated on the surfaces to be connected to the ceramic body 1. Eutectics other than Cu / Cu 2 0 can also be used for the connection.
  • the surfaces of the segments (2) to be connected to the ceramic body (1) must be oxidized before the eutectic connection.
  • all areas can also be subjected to this process step, which in certain cases is a simplification.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Products (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Laminated Bodies (AREA)

Abstract

A collector for electric machines, including a rotationally symmetrical sintered ceramic body and a plurality of radially disposed metallic segments which are separated from each other by one interspace each and which are bonded to the ceramic body via a eutectic intermediate layer. The segments are bonded to the ceramic body in accordance with the eutectic method by being surface-oxidized on their inside narrow side and radially pressed against the ceramic body with the totality being brought to the melting temperature corresponding to the metal/metal-oxide eutectic and subsequently being cooled down again. A preferred embodiment includes: copper segments on an Al2O3 ceramic body.

Description

Die Erfindung geht aus von einem Kollektor nach der Gattung des Oberbegriffs des Anspruchs 1 und einem Verfahren zu dessen Herstellung nach der Gattung des Oberbegriffs des Anspruchs 6.The invention relates to a collector according to the preamble of claim 1 and a method for its production according to the preamble of claim 6.

Kollektoren für elektrische Maschinen bestehen aus radial angeordneten, zentralsymmetrisch ausgerichteten, einen zylindrischen Rotationskörper bildenden metallischen Segmenten (Kupferlamellen), welche voneinander isoliert und durch Ringe zusammengehalten sind. Beim sogenannten Pressringkollektor sind die Segmente schwalbenschwanzförmig ausgebildet und werden durch einen axialen Druck ausübende Pressringe unter Zwischenschaltung von Glimmerisolation zusammengehalten. Die Segmente des Schrumpfringkollektors dagegen sind durch Schrumpfringe zusammengehalten, welche auf das ganze Lamellenpaket radiale Kräfte ausüben. Das letztere muss als Ganzes in allen Fällen gegenüber benachbarten Metallteilen isoliert sein. Zu diesem Zweck werden vorwiegend Glimmer und Glimmerprodukte (Mica) verwendet.Collectors for electrical machines consist of radially arranged, centrally symmetrical metal segments (copper lamellas) forming a cylindrical body of rotation, which are insulated from each other and held together by rings. In the so-called press ring collector, the segments are dovetail-shaped and are held together by press rings exerting axial pressure with the interposition of mica insulation. The segments of the shrink ring collector, on the other hand, are held together by shrink rings, which exert radial forces on the entire plate pack. The latter as a whole must be insulated from neighboring metal parts in all cases. Mica and mica products are mainly used for this purpose.

Kollektoren werden im Betrieb sehr hohen mechanischen und thermischen Beanspruchungen ausgesetzt. Daher werden sie meistens als sogenannte Gewölbedruckkollektoren ausgeführt. Dies bedeutet, dass auch bei den höchsten Umfangsgeschwindigkeiten (Schleuderdrehzahl) benachbarte Lamellen nicht klaffen dürfen, sondern immer noch unter gegenseitigem tangentialem Druck aneinander anliegen müssen. Die Berechnung und Konstruktion dieser herkömmlichen Kollektoren erfordert daher grosse Sorgfalt und Erfahrung. Ihre Fertigung sowie ihre gesamte Technologie (Wärmebehandlung, Formierung) stellt praktisch eine handwerkliche Kunst dar, an die sehr hohe Anforderungen gestellt wird. Dies hängt mit der Neigung zur Instabilität der Mica-Isolation zusammen. Die Glimmerprodukte haben senkrecht zu ihrer Schichtfläche keinerlei Zug- und parallel dazu nur eine verschwindend geringe Scherfestigkeit. Sie dürfen daher nur senkrecht zur Schichtfläche auf Druck belastet werden. Die einzelnen Glimmerplättchen haben die Neigung, sich gegeneinander zu verschieben, was durch ungleichmässige Erwärmung (Anfahren aus dem Stillstand bei Bahnmotoren) oder mechanische Ueberlastung verursacht sein kann. Dadurch können einzelne Lamellen irreversibel verschoben werden und zu Betriebsstörungen führen.In operation, collectors are very high mechanical and exposed to thermal stress. Therefore, they are mostly designed as so-called vault pressure collectors. This means that, even at the highest peripheral speeds (spin speed), adjacent lamellas must not gap, but must still be in contact with each other under mutual tangential pressure. The calculation and design of these conventional collectors therefore requires great care and experience. Their production as well as their entire technology (heat treatment, forming) represents practically a craft art, to which very high demands are made. This is related to the tendency to instability of the mica isolation. The mica products have no tensile strength perpendicular to their layer surface and in parallel only a negligible low shear strength. They may therefore only be subjected to pressure perpendicular to the layer surface. The individual mica platelets have a tendency to move against each other, which can be caused by uneven heating (starting from a standstill in rail engines) or mechanical overload. As a result, individual slats can be moved irreversibly and lead to malfunctions.

Aus dem Vorstehenden geht klar hervor, dass der herkömmliche Kollektor ein recht kompliziertes, zu mechanischen Instabilitäten und geometrischen Veränderungen neigendes Gebilde ist, dessen gesamte Herstellungstechnologie zeitraubend und aufwendig und mit viel handwerklichem Können verbunden ist. Es besteht daher ein Bedürfnis, die Konstruktion zu vereinfachen und das Herstellungsverfahren abzukürzen.From the above it is clear that the conventional collector is a rather complicated structure that tends to mechanical instabilities and geometrical changes, the entire production technology of which is time-consuming and complex and requires a great deal of manual skill. There is therefore a need to simplify the design and shorten the manufacturing process.

Aus der Metallbeschichtungstechnik, wie sie vor allem in der Elektronik bei der Printherstellung angewendet wird, ist das direkte Verbinden von Metallen mit keramischen Werkstoffen nach dem sog. eutektischen Verfahren bekannt. Hierbei wird durch die Erzeugung eines Metall/Metalloxyd-Eutektikums, dessen Schmelzpunkt sich nur knapp unter demjenigen des reinen Metalls befindet, ein im submikroskopisch-atomaren Bereich wirksamer Bindungsmechanismus ausgenutzt. Dieser an den Grenzflächen Metall/Keramik unmittelbar und ohne zusätzliche Zwischenschichten wirksame Bindungsmechanismus gestattet eine fest haftende Verbindung zwischen den beiden ungleichen Komponenten (siehe z.B. J. F. Burgess and C. A. Neugebauer, "The Direct Bonding of Metals to Ceramics by the Gas-Metal Eutectic Method", J. Electrochem. Soc., May 1975, Vol. 122, No. 5; J. F. Burgess, C. A. Neugebauer, G. Flanagan, R. E. Moore, "The Direct Bonding of Metals to Ceramics and Applications. in Electronics", General Electric Report No. 75CRD105, May 1975; US-PS 3 766 634; US-PS 3 911 553).From metal coating technology, as it is used primarily in electronics for print production, the direct connection of metals with ceramic materials by the so-called eutectic method is known. Here, a binding mechanism that is effective in the submicroscopic-atomic range is used by producing a metal / metal oxide eutectic, the melting point of which is only slightly below that of the pure metal. This binding mechanism, which is effective at the metal / ceramic interfaces and without additional intermediate layers, permits a firmly bonded connection between the two dissimilar components (see, for example, JF Burgess and CA Neugebauer, "The Direct Bonding of Metals to Ceramics by the Gas-Metal Eutectic Method", J. Electrochem. Soc., May 1975, Vol. 122, No. 5; JF Burgess, CA Neugebauer, G. Flanagan, RE Moore, "The Direct Bonding of Metals to Ceramics and Applications. In Electronics", General Electric Report No 75CRD105, May 1975; U.S. Patent 3,766,634; U.S. Patent 3,911,553).

Der Erfindung liegt die Aufgabe zugrunde, einen Kollektor für eine elektrische Maschine anzugeben, welche sich als Ganzes möglichst wie ein monolithischer Körper verhält, keinerlei zu mechanischen Instabilitäten neigende isolierende Zwischenschichten enthält und in seinem Aufbau möglichst einfach ist. Das entsprechende Herstellungsverfahren soll mit einfachen Mitteln reproduzierbar sein und keine hohen Anforderungen an handwerkliches Können stellen.The invention is based on the object of specifying a collector for an electrical machine which, as a whole, behaves as much as possible as a monolithic body, does not contain any insulating intermediate layers which tend to mechanical instabilities and is as simple as possible in its construction. The corresponding manufacturing process should be reproducible with simple means and should not place high demands on manual skills.

Diese Aufgabe wird durch die im kennzeichnenden Teil der Ansprüche 1 und 6 angegebenen Merkmale gelöst.This object is achieved by the features specified in the characterizing part of claims 1 and 6.

Die Erfindung wird anhand der nachfolgenden, durch Figuren erläuterten Ausführungsbeispiele beschrieben.The invention is described on the basis of the following exemplary embodiments explained by figures.

Dabei zeigt:

  • Fig. 1 den Längsschnitt durch einen Kollektor mit glattem Keramikkörper,
  • Fig. 2 den Querschnitt durch einen Kollektor mit glattem Keramikkörper,
  • Fig. 3 den Querschnitt durch einen Kollektor mit genutztem Keramikkörper,
  • Fig. 4 verschiedene Segmentformen im Aufriss.
It shows:
  • 1 shows the longitudinal section through a collector with a smooth ceramic body,
  • 2 shows the cross section through a collector with a smooth ceramic body,
  • 3 shows the cross section through a collector with a used ceramic body,
  • Fig. 4 different segment shapes in elevation.

In Fig. 1 ist ein Kollektor mit glattem Keramikkörper im Längsschnitt dargestellt. 1 ist ein rotationssymmetrischer gesinterter Keramikkörper (Al2O3) mit glatter zylindrischer Mantelfläche. 2 stellt ein metallisches Segment (Kupferlamelle) mit rechteckförmigem Querschnitt und ebener innerer Begrenzungsfläche dar. Die Verbindung zwischen 1 und 2 ist durch eine eutektische Zwischenschicht 3 (Cu/Cu20-Eutektikum) gewährleistet. Die innere Begrenzungsfläche des Keramikkörpers 1 kann verschieden gestaltet sein und auch von der Zylinderform abweichen. Insbesondere können aus konstruktiven Gründen der Befestigung auf der Maschinenwelle Absetzungen, Ausnehmungen etc. vorgesehen sein.In Fig. 1, a collector with a smooth ceramic body is shown in longitudinal section. 1 is a rotationally symmetrical sintered ceramic body (Al 2 O 3 ) with a smooth cylindrical surface. 2 represents a metallic segment (copper lamella) with a rectangular cross section and a flat inner boundary surface. The connection between 1 and 2 is ensured by an eutectic intermediate layer 3 (Cu / Cu 2 O eutectic). The inner boundary surface of the ceramic body 1 can be designed differently and also differ from the cylindrical shape. In particular, for constructional reasons, attachments, recesses, etc. can be provided on the machine shaft.

Fig. 2 zeigt den Querschnitt durch den Kollektor gemäss Fig. 1. Die Bezugszeichen entsprechen genau denjenigen der ersten Figur. Es soll noch darauf hingewiesen werden, 'dass die Dicke der eutektischen Zwischenschicht 3 stark übertrieben gezeichnet ist, um ihre Bedeutung hervorzuheben. In Wirklichkeit bewegt sich diese Dicke im Bereich von ca. 5 bis 50 11.FIG. 2 shows the cross section through the collector according to FIG. 1. The reference symbols correspond exactly to those in the first figure. It should also be pointed out that the thickness of the eutectic intermediate layer 3 is drawn in a greatly exaggerated manner in order to emphasize its importance. In reality, this thickness ranges from about 5 to 50 11 .

Fig. 3 stellt einen Kollektor mit genutztem Keramikkörper im Querschnitt dar. 4 ist eine parallel zur Achse des Keramikkörpers 1 in demselben verlaufende Nut, 5 der entsprechende Steg. Die Segmente 2 sind praktisch spielfrei in die Nuten 5 eingelassen. Die übrigen Bezugszeichen entsprechen denjenigen der Fig. 2.Fig. 3 shows a collector with a used ceramic body 4 is a groove running parallel to the axis of the ceramic body 1 in the same, 5 the corresponding web. The segments 2 are embedded in the grooves 5 with virtually no play. The remaining reference numerals correspond to those in FIG. 2.

In Fig. 4 sind verschiedene Formen der Segmente im Aufriss dargestellt. Die stirnseitigen Partien der Segmente 2 weisen jeweils gegen das Ende zu abnehmende radiale Höhe auf. 6 ist ein abgeschrägtes, 7 ein ausgerundetes Ende des Segments 2, während im letzten Fall das Ende des Segmentes 2 eine Entlastungskerbe 8 aufweist.4 shows various shapes of the segments in elevation. The end portions of the segments 2 each have a radial height that decreases towards the end. 6 is a beveled, 7 a rounded end of the segment 2, while in the latter case the end of the segment 2 has a relief notch 8.

AusführungsbeispielEmbodiment Siehe Figuren 1 und 2!See Figures 1 and 2!

Aus technisch reinem Aluminiumoxyd wurde ein dichter Keramikkörper 1 durch Sintern hergestellt. Der Keramikkörper 1 war rotationssymmetrisch und wies im allgemeinen ungefähr eine hohlzylindrische Form folgender Abmessungen und Eigenschaften auf:A dense ceramic body 1 was produced from technically pure aluminum oxide by sintering. The ceramic body 1 was rotationally symmetrical and generally had approximately a hollow cylindrical shape with the following dimensions and properties:

Figure imgb0001
Der Keramikkörper 1 wurde zunächst folgender Vorbehandlung unterworfen:

  • Entfetten: FREON 22, Ultraschall, 10 min.
  • Entfernen organischer Reste: H2SO4 konz., 150°C, 20 min. Entfernen metallischer Reste: Aqua regia, 20°C, 20 min. Destilliertes Wasser, 2 x Ultraschall, 10 min.
  • Trocknen: Aufheizen im Ofen an Luft in 2 Std. auf 1000°C, 20 min. halten, abkühlen auf Raumtemperatur, 4 Std.
Figure imgb0001
 The ceramic body 1 was first subjected to the following pretreatment:
  • Degreasing: FREON 22, ultrasound, 10 min.
  • Removal of organic residues: H 2 SO 4 conc., 150 ° C, 20 min. Removal of metallic residues: Aqua regia, 20 ° C, 20 min. Distilled water, 2 x ultrasound, 10 min.
  • Drying: Heating in the oven in air in 2 hours at 1000 ° C, 20 min. hold, cool to room temperature, 4 hours

Zur Herstellung der Segmente 2 wurde von einer massiven Elektrolytkupferplatte von 176 x 75 x 5 mm ausgegangen. Auf einer Seite wurden in die Kupferplatte parallele Nuten von 0,6 mm Breite, 3,5 mm Tiefe und 4,75 mm Mittenabstand eingefräst. Hierauf wurde die gefräste Kupferplatte zwecks Entspannung und Erweichung des Werkstoffs während 20 min. bei einer Temperatur von 800oC unter Schutzgas (90 % Ar/ 10 % H2) geglüht. Die abgekühlte Kupferplatte wurde auf der ebenen, nicht gefrästen Seite mit Abdecklack überzogen und zwecks oberflächlicher Oxydation während 20 min. in ein chemisches Bad folgender Zusammensetzung eingetaucht:

Figure imgb0002
A massive electrolytic copper plate of 176 x 75 x 5 mm was used to manufacture segments 2. On one side, parallel grooves of 0.6 mm width, 3.5 mm depth and 4.75 mm center distance were milled into the copper plate. Then the milled copper plate was used for relaxation and softening of the material for 20 min. annealed at a temperature of 800 o C under protective gas (90% Ar / 10% H 2 ). The cooled copper plate was coated on the flat, not milled side with masking lacquer and for 20 minutes for surface oxidation. immersed in a chemical bath of the following composition:
Figure imgb0002

Anschliessend wurde die Kupferplatte während 2 x 10 min. in destilliertem Wasser gespült und der Abdecklack auf der Aussenseite abgelöst. Die Kupferplatte wurde nun, die genutete Seite nach innen zeigend, um den Keramikkörper 1 herumgebogen, so dass ein vollständiger hohlzylindrischer Körper von 66 mm Aussendurchmesser gebildet wurde. In dieser Stellung wurde der gebogene Kupferkörper durch Umwickeln von Molybdändraht von 0,2 mm Dicke unter Anwendung einer Zugspannung radial an den Keramikkörper 1 angepresst und festgehalten.The copper plate was then 2 x 10 min. rinsed in distilled water and the topcoat on the outside removed. The copper plate was now bent around the ceramic body 1, with the grooved side facing inwards, so that a complete hollow cylindrical body with an outer diameter of 66 mm was formed. In this position, the bent copper body was pressed radially against the ceramic body 1 by wrapping molybdenum wire with a thickness of 0.2 mm using a tensile stress.

In Abweichung zu dieser Methode wird der Kupferkörper durch eine aus einer Nickel-Superlegierung (z.B. IN 100) bestehende Haltevorrichtung unter Zwischenschaltung eines dünnen Molybdänblechs (ca. 0,05 mm Dicke) zwecks Vermeidung einer unerwünschten metallurgischen Verbindung zwischen Werkstück und Werkzeug an den Keramikkörper 1 angedrückt.In deviation from this method, the copper body is attached to the ceramic body 1 by a holding device made of a nickel superalloy (e.g. IN 100) with the interposition of a thin molybdenum sheet (approx. 0.05 mm thick) in order to avoid an undesired metallurgical connection between the workpiece and the tool pressed.

Das Ganze wurde nun langsam in einen Rohrofen geschoben, so dass das Werkstück in Verlaufe von 30 min. die Temperatur von 10720C (Toleranz ± 2°C) erreichte. Dadurch bildete sich an den zuvor oxydierten Grenzflächen zwischen Kupferkörper und Keramikkörper 1 eine eutektische Zwischenschicht 3 (Cu/Cu20-Eutektikum), welche einen Schmelzpunkt von 1065°C besitzt. Das reine Kupfer hat demgegenüber einen Schmelzpunkt von 1083°C. Die sich bildende flüssige eutektische Phase benetzte sowohl den Keramikkörper 1 wie den Kupferkörper ausgezeichnet, wobei sie in die Poren des ersteren eindrang. Werkstück und Spannvorrichtung wurden während 25 min auf der Temperatur von 1072°C belassen und anschliessend im Verlaufe von weiterer 30 min. auf Raumtemperatur abgekühlt. Dabei erstarrte die zuvor flüssige Phase und bildete eine feste Verbindung (Zwischenschicht 3) zwischen Kupferkörper und Keramikkörper 1. Die ganze Wärmebehandlung des eutektischen Verbindungsprozesses wurde unter Schutzgas (hochreiner Stickstoff mit weniger als 5 ppm H20 und 02) durchgeführt.The whole thing was then slowly pushed into a tube furnace, so that the workpiece over 30 minutes. reached the temperature of 1072 0 C (tolerance ± 2 ° C). As a result, a eutectic intermediate layer 3 (Cu / Cu 2 0 eutectic), which has a melting point of 1065 ° C., was formed at the previously oxidized interfaces between the copper body and ceramic body 1. In contrast, pure copper has a melting point of 1083 ° C. The liquid eutectic phase that forms wets both the ceramic body 1 and the copper body excellently, penetrating into the pores of the former. Workpiece and clamping device were left at a temperature of 1072 ° C for 25 min and then for a further 30 min. cooled to room temperature. The previously liquid phase solidified and formed a firm connection (intermediate layer 3) between the copper body and ceramic body 1. The entire heat treatment of the eutectic connection process was carried out under protective gas (high-purity nitrogen with less than 5 ppm H 2 0 and 0 2 ).

Nach der Abkühlung wurde das Werkstück aus der Halterung entfernt und der hohlzylindrische Kupferkörper bis zum Durchbruch der Nuten auf einen Aussendurchmesser von 63 mm abgedreht. Die durch diesen Verfahrensschritt entstandenen freigelegten Segmente 2 haben nun keinerlei Verbindung mehr untereinander.After cooling, the workpiece was removed from the holder and the hollow cylindrical copper body was turned to an outer diameter of 63 mm until the grooves broke. The exposed segments 2 created by this method step no longer have any connection with one another.

Ausführunssbeispiel II:Example II: Siehe Figur 3!See Figure 3!

Aus Aluminiumoxyd wurde durch Strangpressen und Sintern ein an seinem äusseren Umfang mit Nuten 4 und Stegen 5 versehener Keramikkörper 1 hergestellt. Seine Eigenschaften entsprachen denjenigen von Beispiel I. Die Abmessungen betrugen:

Figure imgb0003
A ceramic body 1 provided on its outer periphery with grooves 4 and webs 5 was produced from aluminum oxide by extrusion and sintering. Its properties corresponded to those of Example I. The dimensions were:
Figure imgb0003

Der Keramikkörper 1 wurde gemäss Beispiel I vorbehandelt.The ceramic body 1 was pretreated according to Example I.

Die Segmente 2 aus Elektrolytkupfer hatten rechteckigen Querschnitt und besassen folgende Abmessungen:

Figure imgb0004
The segments 2 made of electrolytic copper had a rectangular cross section and had the following dimensions:
Figure imgb0004

Die Segmente 2 wurden in einem chemischen Bad wie in Beispiel I angegeben oberflächlich oxydiert. Dann wurden sie mittels einer warmfesten Spannvorrichtung radial in die Nuten 4 des Keramikkörpers eingepresst und festgehalten. Die Wärmebehandlung zwecks Erzeugung der eutektischen Zwischenschicht 3 erfolgte genau gemäss Beispiel I. Die sich dabei bildende eutektische Zwischenschicht 3 umfloss U-förmig die Segmente 2 und verband sie nach der Erstarrung mit dem Keramikkörper 1 allseitig längs der gesamten Nut 4. Dieses Verfahren wird insbesondere für die Herstellung von Kollektoren grösserer Abmessungen angewendet.The segments 2 were surface oxidized in a chemical bath as indicated in Example I. Then they were pressed radially into the grooves 4 of the ceramic body and held in place by means of a heat-resistant clamping device. The heat treatment for the purpose of producing the eutectic intermediate layer 3 was carried out exactly according to the example game I. The eutectic intermediate layer 3 that forms flows around the segments 2 in a U-shape and, after solidification, connects them to the ceramic body 1 on all sides along the entire groove 4. This method is used in particular for the production of collectors of larger dimensions.

Die Erfindung ist nicht auf die Ausführungsbeispiele begrenzt. Die Temperatur für die Erhitzung der zu verbindenden Werkstückteile darf im Falle des Cu/Cu20-Eutektikums 1075 i 7°C betragen. Die Enden der Segmente 2 werden mit abnehmender radialer Höhe ausgeführt, um Eigenspannungen abzubauen und Spannungsspitzen an den Unstetigkeitsstellen zu vermeiden. Dazu dienen die in Figur 4 a bis c dargestellten abgeschrägten (6) oder ausgerundeten (7) Enden der Segmente 2 sowie die Entlastungskerbe 8. Der Keramikkörper 1 kann aus Zirkonoxyd oder aus mit Zirkonoxyd dotiertem Aluminiumoxyd bestehen. Die Segmente 2 können auch aus einem anderen Werkstoff als Kupfer oder eine Kupferlegierung bestehen und lediglich an den mit dem Keramikkörper 1 zu verbindenden Flächen verkupfert sein. Auch andere Eutektika als Cu/Cu20 sind zum Verbinden verwendbar.The invention is not limited to the exemplary embodiments. In the case of the Cu / Cu 2 0 eutectic, the temperature for heating the workpiece parts to be connected may be 1075 i 7 ° C. The ends of the segments 2 are designed with a decreasing radial height in order to reduce residual stresses and to avoid stress peaks at the points of discontinuity. The beveled (6) or rounded (7) ends of the segments 2 shown in FIGS. 4 a to c and the relief notch 8 are used for this purpose. The ceramic body 1 can consist of zirconium oxide or of aluminum oxide doped with zirconium oxide. The segments 2 can also consist of a material other than copper or a copper alloy and can only be copper-plated on the surfaces to be connected to the ceramic body 1. Eutectics other than Cu / Cu 2 0 can also be used for the connection.

Die Vorteile des neuen Kollektors lassen sich wie folgt zusammenfassen:

  • - Vereinfachung der Fertigung und Verkürzung der Herstellungsdauer, insbesondere Fortfall des "Formierens" (Wärmebehandlung).
  • - Geringere Anforderungen an handwerkliches Können bei der Fertigung.
  • - Einfacher, monolithischer Aufbau des Kollektors.
  • - Wegfall von zu Kurzschlüssen und Massenschlüssen neigenden Konstruktionselementen.
  • - Hohe thermische Ueberlastbarkeit, hohe Temperaturwechselbeständigkeit einzelner Segmente ohne Gefahr irreversibler Verschiebungen.
  • - Vereinfachung und Erleichterung von Ueberhol- und Reparaturarbeiten im Betrieb.
  • - Wegfall des.zeitraubenden, periodischen Ausfräsens der mit Glimmerprodukten ausgefüllten Zwischenräume (Nuten) zwischen den Segmenten im Betrieb.
The advantages of the new collector can be summarized as follows:
  • - Simplification of production and shortening of the production time, in particular the elimination of "forming" (heat treatment).
  • - Lower demands on manual skills in manufacturing.
  • - Simple, monolithic structure of the collector.
  • - Elimination of construction elements that tend to short circuits and mass short circuits.
  • - High thermal overload capacity, high thermal shock resistance of individual segments without the risk of irreversible displacements.
  • - Simplification and facilitation of overhaul and repair work in the company.
  • - Eliminate the time-consuming, periodic milling of the interstices (grooves) between the segments in the company filled with mica products.

Im allgemeinen müssen mindestens die mit dem Keramikkörper (1) zu verbindenden Flächen der Segmente (2) vor dem eutektischen Verbinden oxydiert werden. Es können aber selbstverständlich auch alle Flächen diesem Verfahrensschritt unterzogen werden, was in gewissen Fällen eine Vereinfachung darstellt.In general, at least the surfaces of the segments (2) to be connected to the ceramic body (1) must be oxidized before the eutectic connection. Of course, all areas can also be subjected to this process step, which in certain cases is a simplification.

Claims (8)

1. Kollektor für eine elektrische Maschine, dadurch gekennzeichnet, dass er aus einem rotationssymmetrischen zentralen gesinterten Keramikkörper (1) und radial stehenden, auf dessen Mantelfläche durch je einen Zwischenraum voneinander getrennt angeordneten und mit demselben über eine eutektische Zwischenschicht (3) verbundenen metallischen Segmenten (2) besteht.1. Collector for an electrical machine, characterized in that it consists of a rotationally symmetrical central sintered ceramic body (1) and radially standing, on the lateral surface of each of which is separated by an intermediate space and connected to it via a eutectic intermediate layer (3) connected to metallic segments ( 2) exists. 2. Kollektor nach Anspruch 1, dadurch gekennzeichnet, dass der Keramikkörper (1) aus dicht gesintertem Aluminiumoxyd oder aus mit Zirkonoxyd dotiertem Aluminiumoxyd oder aus Zirkonoxyd, die metallischen Segmente (2) aus Kupfer oder einer Kupferlegierung und die Zwischenschicht (3) aus dem Eutektikum Kupfer/Kupferoxydul bestehen.2. Collector according to claim 1, characterized in that the ceramic body (1) made of densely sintered aluminum oxide or of zirconium oxide-doped aluminum oxide or zirconium oxide, the metallic segments (2) made of copper or a copper alloy and the intermediate layer (3) made of the eutectic Copper / copper oxide exist. 3. Kollektor nach Anspruch 1, dadurch gekennzeichnet, dass der Keramikkörper (1) eine glatte zylindrische Mantelfläche besitzt und dass die Segmente (2) auf der Innenseite tangentiale ebene Begrenzungsflächen aufweisen.3. Collector according to claim 1, characterized in that the ceramic body (1) has a smooth cylindrical outer surface and that the segments (2) have tangential flat boundary surfaces on the inside. 4. Kollektor nach Anspruch 1, dadurch gekennzeichnet, dass der Keramikkörper (1) auf seiner äusseren Begrenzungsfläche mit Nuten (4) und Stegen (5) versehen ist.4. Collector according to claim 1, characterized in that the ceramic body (1) is provided on its outer boundary surface with grooves (4) and webs (5). 5. Kollektor nach Anspruch 1, dadurch gekennzeichnet, dass die metallischen Segmente (2) an ihren Stirnseiten eine gegen das Ende zu abnehmende radiale Höhe besitzen oder mit ausgerundeten Entlastungskerben versehen sind.5. Collector according to claim 1, characterized in that the metallic segments (2) have at their end faces a radial height to be reduced towards the end or are provided with rounded relief notches. 6. Verfahren zur Herstellung eines Kollektors für eine elektrische Maschine, dadurch gekennzeichnet, dass zunächst ein rotationssymmetrischer Keramikkörper (1) gesintert sowie eine Vielzahl von metallischen Segmenten (2) mindestens auf ihren innenliegenden Schmalseiten oberflächlich oxydiert und unter Aufwendung eines radial wirkenden Aufpressdrucks und um die Mantelfläche des Keramikkörpers (1) angeordnet werden und das Ganze in einem Ofen auf die für die Erzeugung eines Eutektikums Metall/Metalloxyd erforderliche Temperatur erhitzt und nach dem eutektischen Verfahren zur Verbindung von Keramik- und Metallteilen behandelt und schliesslich auf Raumtemperatur abgekühlt wird.6. Method of making a collector for one Electrical machine, characterized in that first a rotationally symmetrical ceramic body (1) is sintered and a plurality of metallic segments (2) are surface-oxidized at least on their inner narrow sides and are arranged using a radially acting pressing pressure and around the outer surface of the ceramic body (1) and the whole is heated in an oven to the temperature required for producing a metal / metal oxide eutectic and treated using the eutectic method for connecting ceramic and metal parts and finally cooled to room temperature. 7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass ein Keramikkörper (1) aus Aluminiumoxyd dicht gesintert und mit Segmenten (2) aus Kupfer unter Erzeugung einer eutektischen Zwischenschicht (3) verbunden wird, indem das Ganze auf eine Temperatur von 1072 1 7oC gebracht und anschliessend auf Raumtemperatur abgekühlt wird.7. The method according to claim 6, characterized in that a ceramic body (1) made of aluminum oxide is densely sintered and connected to segments (2) made of copper to produce a eutectic intermediate layer (3) by the whole to a temperature of 1072 1 7 o C is brought and then cooled to room temperature. 8. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass eine auf einer Seite mit parallelen rechteckigen Längsnuten von einer Breite, welche dem tangentialen Abstand der Segmente (2) entspricht, versehene Kupferplatte derart um den Keramikkörper (1) gebogen wird, dass die Längsnuten auf die Innenseite und parallel zur Längsachse des Keramikkörpers zu liegen kommen, wobei die Aussenseite einen glatten zylindrischen Körper bildet, dass das Ganze in eine, radiale Druckkräfte ausübende Vorrichtung gespannt und auf die eutektische Temperatur erwärmt und wieder auf Raumtemperatur abgekühlt wird, worauf der aussenliegende zylindrische Kupfermantel bis zum Durchbruch der Längsnuten abgedreht wird.8. The method according to claim 6, characterized in that a copper plate provided on one side with parallel rectangular longitudinal grooves of a width which corresponds to the tangential distance of the segments (2) is bent around the ceramic body (1) such that the longitudinal grooves the inside and parallel to the longitudinal axis of the ceramic body come to lie, the outside forming a smooth cylindrical body, that the whole is clamped in a device that exerts radial pressure forces and heated to the eutectic temperature and cooled again to room temperature, whereupon the outer cylindrical copper jacket is turned until the longitudinal grooves break through.
EP84105347A 1983-06-03 1984-05-11 Commutator for an electric machine and method of making it Expired EP0127801B1 (en)

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AT84105347T ATE23080T1 (en) 1983-06-03 1984-05-11 COLLECTOR FOR AN ELECTRICAL MACHINE AND PROCESS FOR ITS MANUFACTURE.

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CH307183 1983-06-03
CH3071/83 1983-06-03

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FR2599904A1 (en) * 1986-06-05 1987-12-11 Alsthom Collector for a rotating electrical machine and process for manufacturing this collector
EP0290341A1 (en) * 1987-05-04 1988-11-09 Gec Alsthom Sa Commutator for an electrical rotating machine, and production process of this commutator
WO1997042688A1 (en) * 1996-05-02 1997-11-13 Robert Bosch Gmbh Method of producing a commutator
WO1998010493A1 (en) * 1996-09-03 1998-03-12 Svein Hestevik Commutator
WO2000033428A1 (en) * 1998-11-27 2000-06-08 Kirkwood Industries Gmbh Commutation device, especially a commutator, and method for producing such a device
RU2684995C1 (en) * 2018-05-17 2019-04-16 Акционерное общество "Уралэлектромедь" Method for manufacturing collector plates
RU2710758C1 (en) * 2019-08-15 2020-01-13 Дмитрий Геннадьевич Дудкин Method of making collector plates

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JPS61218084A (en) * 1985-03-25 1986-09-27 株式会社　徳力本店 Slide contact
JPH027766U (en) * 1988-06-24 1990-01-18
JPH05219690A (en) * 1991-02-28 1993-08-27 Hitachi Ltd Ceramic sliding collector
JPH05226047A (en) * 1991-03-18 1993-09-03 Hitachi Ltd Commutator with built-in capacitor and manufacture thereof
US5108026A (en) * 1991-05-14 1992-04-28 Motorola Inc. Eutectic bonding of metal to ceramic
US5876859A (en) * 1994-11-10 1999-03-02 Vlt Corporation Direct metal bonding
US6056186A (en) * 1996-06-25 2000-05-02 Brush Wellman Inc. Method for bonding a ceramic to a metal with a copper-containing shim
DE69839598D1 (en) * 1997-08-21 2008-07-24 Aisan Ind COMMUTATOR WITH IMPROVED SEGMENT CONNECTIONS
DE10352829A1 (en) * 2003-11-12 2005-06-23 Hilti Ag Commutator for commutator motors has supporting body consisting glass, e.g. transparent, bright glass, with electrically conductive segments on external peripheral surface; supporting body can be section of glass tube
RU2629377C1 (en) * 2016-03-21 2017-08-29 Федеральное государственное бюджетное образовательное учреждение высшего образования "Дальневосточный государственный университет путей сообщения" (ДВГУПС) Commutator machine

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FR893126A (en) * 1942-03-30 1944-05-31 Hermes Patentverwertungs Gmbh Contact switch for electrical machines
GB713982A (en) * 1952-03-07 1954-08-18 Metro Cutanit Ltd Improvements relating to the manufacture of commutator segments
US3411197A (en) * 1963-08-24 1968-11-19 Kuibyshevsky Aviat I Method for continuously manufacturing commutator segments
CH449111A (en) * 1964-06-11 1967-12-31 Philips Nv Electric collector machine
GB1404560A (en) * 1973-11-17 1975-09-03 Gen Electric Adhesively bonded commutator
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FR2339277A1 (en) * 1976-01-20 1977-08-19 Kautt & Bux Kg MANIFOLD AND METHOD USED FOR ITS MANUFACTURING

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2599904A1 (en) * 1986-06-05 1987-12-11 Alsthom Collector for a rotating electrical machine and process for manufacturing this collector
EP0290341A1 (en) * 1987-05-04 1988-11-09 Gec Alsthom Sa Commutator for an electrical rotating machine, and production process of this commutator
FR2615049A1 (en) * 1987-05-04 1988-11-10 Alsthom COLLECTOR FOR ROTATING ELECTRICAL MACHINE AND MANUFACTURING METHOD THEREFOR
WO1997042688A1 (en) * 1996-05-02 1997-11-13 Robert Bosch Gmbh Method of producing a commutator
WO1998010493A1 (en) * 1996-09-03 1998-03-12 Svein Hestevik Commutator
WO2000033428A1 (en) * 1998-11-27 2000-06-08 Kirkwood Industries Gmbh Commutation device, especially a commutator, and method for producing such a device
US6710500B1 (en) 1998-11-27 2004-03-23 Kirkwood Industries Gmbh Commutation device, especially a commutator, and method for producing such a device
RU2684995C1 (en) * 2018-05-17 2019-04-16 Акционерное общество "Уралэлектромедь" Method for manufacturing collector plates
RU2710758C1 (en) * 2019-08-15 2020-01-13 Дмитрий Геннадьевич Дудкин Method of making collector plates

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CA1226324A (en) 1987-09-01
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DE3461040D1 (en) 1986-11-27
ATE23080T1 (en) 1986-11-15

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