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WO1991006992A1 - Collecteurs pour machines electriques - Google Patents

Collecteurs pour machines electriques Download PDF

Info

Publication number
WO1991006992A1
WO1991006992A1 PCT/GB1990/001668 GB9001668W WO9106992A1 WO 1991006992 A1 WO1991006992 A1 WO 1991006992A1 GB 9001668 W GB9001668 W GB 9001668W WO 9106992 A1 WO9106992 A1 WO 9106992A1
Authority
WO
WIPO (PCT)
Prior art keywords
copper
commutator
conductors
segments
base
Prior art date
Application number
PCT/GB1990/001668
Other languages
English (en)
Inventor
Arthur Gordon Copus
Original Assignee
Nelco Holdings Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nelco Holdings Limited filed Critical Nelco Holdings Limited
Publication of WO1991006992A1 publication Critical patent/WO1991006992A1/fr

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00Rotary current collectors, distributors or interrupters
    • H01R39/02Details for dynamo electric machines
    • H01R39/04Commutators
    • H01R39/06Commutators other than with external cylindrical contact surface, e.g. flat commutators

Definitions

  • This invention relates to commutators for electrical machines, and to manufacture of commutators.
  • An electrical machine of the type to which this invention relates typically comprises a rotating shaft carrying armature windings, with electrical connection to the armature windings being made through brushes contacting a segmented commutator that rotates with the shaft and to which the armature windings are connected.
  • the preferred material for the commutator is copper, and the armature windings are usually connected to preformed segments of the commutator by brazing or welding.
  • the copper commutators required for such electrical machines are expensive to produce, not only because each one requires a large amount of copper which is a costly raw material, but also because the shaping of each commutator segment involves a complicated drawing process. Moreover, fitting of the armature windings into the commutator during construction of the machine is a slow process which usually has to be performed manually in order to obtain the necessary accuracy.
  • a commutator structure made from a printed circuit board is described in GB 2056788 for use in a micromotor. However, in this instance care is taken to have the winding contact zone separate from the brush track and the technique is not suitable for larger motors.
  • the present invention addresses, separately and together, the problem of commutator structure and armature winding contacts.
  • the segments of a commutator of an electrical machine are made by spraying copper or other metal on to an insulating base to provide a layer of material for the segments. Such a technique avoids the use of preformed commutator segments and so provides a cheaper and/or quicker method of manufacture of the commutator.
  • a particular aspect of the invention is the simplification of attachment of the ends of the armature windings to respective armature segments.
  • the commutator comprises a base of insulating material, and wherein in a first stage the conductors are fitted through channels in the base, and in a second stage the ends of the conductors are sprayed with copper to provide the material for the commutator segments and simultaneously to effect the connection between the conductors and the segments.
  • the copper may then be shaped to form the commutator segments.
  • Figures 1A and IB show a first stage in the process according to the invention
  • Figures 2A and 2B show a second stage
  • Figures 3A and 3B show a final stage in the process according to the invention.
  • Figure 1A shows a partial sectional view of an electric machine.
  • Armature laminations 1 are wound with armature conductors 2. These armature conductors may be round wire, rectangular or stranded, but in the illustrated embodiment they are shown as round wire conductors.
  • free ends 3 of the armature conductors pass through slots or holes 4 in an insulating former or plate 5 which forms the base shape for the commutator.
  • the commutator rotates on motor axis 6, and the insulating plate is therefore, for a face-plate type commutator, preferably disc-shaped with a substantially circular periphery.
  • Figure IB shows an end view of a small section of the insulating plate viewed from point X in Figure 1A during the first stage of the process.
  • Figure 2A illustrates a second stage in the construction of the commutator contacts.
  • the free ends 3 of the armature conductors are first trimmed, if necessary, so that they do not protrude much beyond the face 7 of the insulating plate.
  • a coating 8 of copper or other metal is then sprayed on to the face of the insulating plate in a layer which completely covers the face of the plate in the region of the conductors, as shown in Figure 2B.
  • a surface treatment such as sand blasting, may be used to aid keying.
  • the copper is spray-coated on to the face of the plate in a layer having a depth sufficient to cover the ends of the conductors with some excess, and to allow the surface of the copper to be machined in the final stage of the process.
  • the sprayed copper layer will have a depth of 2mm, which is machined down to about 1.5mm.
  • the final stage which involves shaping the layer of copper, is shown in Figures 3A and 3B.
  • the sprayed copper coating is machined to size, and the rough edges at the inner and outer periphery of the spray-coated area on the disc are removed.
  • the copper layer is then separated into wedge-shaped commutator segments 9, as shown in Figure 3B, by cutting slots 10 in the copper layer between each group of conductors, such that each group of conductors is electrically isolated from the others.
  • the face-plate commutator comprising a segmented layer of sprayed copper on an insulating former, is now ready for use.
  • the brushes of the electrical machine are able to form electrical contact with the smooth copper surface 11 of each of the segments 9 of the commutator, as in any conventional solid copper commutator.
  • a substantial proportion of the commutator is made of an insulating material, such as a rigid plastic which is both cheaper than copper, and lighter giving a lighter load for the rotor assembly.
  • the commutator base is also more easily formed into the required shape than is machining a copper block, and the subsequent copper deposition process enables easier segment production than separate machining of segments and subsequent assembly.
  • the commutator may be formed as a single, integral structure, thereby eliminating both assembly and alignment problems.
  • the ends of the armature windings are also firmly embedded in the copper layer giving good electrical and mechanical contact, and again simplifying or removing assembly and alignment problems.
  • the copper swarf which is produced by the machining in the final stage of the process may be collected and recycled for future use in the copper spraying stage.
  • the process is therefore very economical in its use of copper in comparison to ordinary methods of construction of commutators.
  • the polyester dipping (or other equivalent process) can conveniently take place after the armature has been wound and the ends passed through the apertures in the insulating commutator disc.
  • the polyester thus helps to form a mechanical bond between the wires and the disc.
  • the ends of the wires and the disc may then be machined both providing polyester free wire surface for electrical contact and a rough surface to aid keying of the sprayed copper.

Landscapes

  • Motor Or Generator Current Collectors (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

Les lames conductrices d'un collecteur d'une machine électrique sont réalisées par projection d'un métal sur un fond isolant pour former le matériau constitutif des lames.
PCT/GB1990/001668 1989-11-01 1990-10-31 Collecteurs pour machines electriques WO1991006992A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8924580.7 1989-11-01
GB8924580A GB2238669A (en) 1989-11-01 1989-11-01 Sprayed commutators and winding connections thereto

Publications (1)

Publication Number Publication Date
WO1991006992A1 true WO1991006992A1 (fr) 1991-05-16

Family

ID=10665514

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1990/001668 WO1991006992A1 (fr) 1989-11-01 1990-10-31 Collecteurs pour machines electriques

Country Status (2)

Country Link
GB (1) GB2238669A (fr)
WO (1) WO1991006992A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2753849A1 (fr) * 1996-09-26 1998-03-27 Valeo Equip Electr Moteur Induit de machine electrique tournante et demarreur de vehicule automobile comportant un tel induit

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2373900A1 (fr) * 1976-12-07 1978-07-07 Bosch Siemens Hausgeraete Collecteur plat pour machines electriques, notamment pour petits moteurs d'appareils menagers electriques
GB2056788A (en) * 1979-06-25 1981-03-18 Portescap Direct current micromotor

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH364301A (fr) * 1959-05-25 1962-09-15 S E A Societe D Electronique E Induit de machine électrique tournante à entrefer axial
GB1193014A (en) * 1967-04-03 1970-05-28 Photocircuits Corp Aluminum Armature and Method for Making Same
GB2125635B (en) * 1982-08-10 1987-06-10 Papst Motoren Gmbh & Co Kg Direct current machine
JPS63198557A (ja) * 1987-02-12 1988-08-17 Mitsubishi Electric Corp 直流電動機

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2373900A1 (fr) * 1976-12-07 1978-07-07 Bosch Siemens Hausgeraete Collecteur plat pour machines electriques, notamment pour petits moteurs d'appareils menagers electriques
GB2056788A (en) * 1979-06-25 1981-03-18 Portescap Direct current micromotor

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2753849A1 (fr) * 1996-09-26 1998-03-27 Valeo Equip Electr Moteur Induit de machine electrique tournante et demarreur de vehicule automobile comportant un tel induit

Also Published As

Publication number Publication date
GB8924580D0 (en) 1989-12-20
GB2238669A (en) 1991-06-05

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