DRUM-BOUND COMMUTATOR AND ITS MANUFACTURING PROCESS Russian patent published in 2006 - IPC H01R43/08 H01R39/04 

FIELD: electrical engineering; characteristic features of drum-bound commutator mechanical design.

SUBSTANCE: proposed process for manufacturing drum-bound commutator that has carrying frame 1 in the form of bushing made of molded insulating material, plurality of conducting metal segments 3, 3', and same quantity of angle segments 4 electrically connected to conducting segments 3, 3' includes following operations: production of conducting metal blank incorporating plurality of conducting segments of which every two adjacent ones are interconnected through jumper 20, distance from radially internal surfaces of jumpers 20 to commutator axis 2 corresponding in effect to distance from radially external surfaces of conducting segments 3, 3' to commutator axis 2; manufacture of angle bushing whose external surface 26 is essentially shaped as circular cylinder, at least its radially internal surface and one axially butt-end surface being metal-plated; connection of conducting blank with angle bushing in axial direction to form electricity conducting contact areas 17 between conducting segments 3, 3' and metal-plated end surface of angle bushing; extrusion of carrying frame 1 made of molded insulating material in extrusion tool onto composite assembly of conducting blank and angle bushing, metal-plated radially internal surface of angle bushing being covered with molded material; removal of jumper 20 to form closed annular surface 19 in the form of circular cylinder with alternating molded material areas and metal ones; formation of angle segments 4 by making axial notches 16 passing in radial direction to carrying frame 1 and disposed in axial planes, each one between two conducting segments 3, 3', closed annular surface 19 in the form of circular cylinder with alternating molded material areas and metal ones being at least partially retained. Drum-bound commutator manufactured in this way is characterized in closed annular surface 19 disposed close to connecting lugs 8 and made in effect in the form of circular cylinder with alternating areas of molded material and metal and with metal-plated inner surface of angle segments 4 connected to carrying frame.

EFFECT: enhanced reliability and service life, reduced space requirement of commutator, strict requirements to working temperatures without raising resistance, ability of damage-free welding of rotor winding wire to conducting segments.

21 cl, 11 dwg