METHOD AND DEVICE FOR PRODUCING AN ELECTRIC MACHINE WITH A COMMUTATOR

• US 20100295409A1
• Filed: 09/17/2007
• Published: 11/25/2010
• Est. Priority Date: 09/29/2006
• Status: Active Grant

• Current Assignee: Robert Bosch GmbH
• Original Assignee: Robert Bosch GmbH
• Inventors: Diedrichs, Axel, Friedmann, Andreas, Herm, Werner, Seiler-Wegner, Edgar, Huber, Helmut, Neubauer, Achim, Altmeyer, Dirk, Chaumet, Pascal
• Granted Patent: US 8,294,327 B2
• Time in Patent Office: Days
• US Class Current: 310/234
• CPC Class Codes: H01R 39/32 Connections of conductor to commutator segment
• CPC Class Codes: H01R 43/06 Manufacture of commutators
• CPC Class Codes: H02K 13/04 Connections between commutator segments and windings
• CPC Class Codes: H02K 15/0056 Manufacturing winding connections
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly

Abstract

The invention relates to a method and device for producing an electric machine, an electric machine with a commutator, having commutator hooks for fixing electric wire windings with solder arranged between the commutator hooks and the wire winding and two electrodes arranged adjacent to each other which are pressed against the commutator hooks. An electric current is passed through the commutator hooks by means of electrodes such that the solder melts and forms a connection to the wire winding.

Claims

1-14. -14. (canceled)

15. A method of producing an electric motor with a commutator, wherein the commutator comprises at least one commutator hook for fixing at least one electric wire winding, the method comprising:

arranging a solder between the at least one commutator hook and the at least one wire winding;

pressing a pair of electrodes that are arranged adjacent to each other against the at least one commutator hook; and

passing an electric current through the at least one commutator hook via the two electrodes to melt the solder and form a connection to the wire winding.

16. The method of claim 15, further comprising pressing a free shank of the at least one commutator hook about a bending area, that is formed at a counter surface, against the counter surface with the pair of the electrodes, wherein the at least one wire winding is positioned between the free shank and the counter surface.

17. The method of claim 16, further comprising pressing the free shank with the pair of electrodes mechanically in a direction of the counter surface prior to passing current through the at least one commutator hook.

18. The method of claim 15, further comprising passing current through the at least one commutator hook until an isolation of the wire winding evaporates and the free shank is embossed warmly.

19. The method of claim 16, further comprising pressing the pair of electrodes against the at least one commutator hook after turning off the current in order to conduct warmth away from the at least one commutator hook into the pair of electrodes.

20. The method of claim 15, wherein the pair of electrodes lie on the at least one commutator hook in a distance of between 0.5 mm to 3 mm, and wherein the pair of electrodes span over an entire circumferential area of the at least one commutator hook

21. The method of claim 15, further comprising forming the solder from at least one of:

silver; and

tin, wherein the solder melts or alloys at a temperature between 200°

C.-300°

C.

22. The method of claim 15, further comprising layering at least one of:

the at least one commutator hook; and

the counter surface with solder prior to inserting the wire wiring into the at least one commutator hook.

23. The method of claim 16, further comprising forming the at least one commutator hook and the counter surface from copper, wherein the copper is in solid state during electric current conduction.

24. The method of claim 16, further comprising forming the counter surface as a part of a cylinder barrel that provides a radial extension, wherein the radial extension is designed as a carrier for a carbon-running surface that works together with a wiper contact of the electric motor.

25. A device for connecting a wire winding with a commutator hook of a commutator, comprising:

a solder that is arranged between the commutator hook and the wire winding; and

a pair of electrodes that are arranged adjacent to each other and are pressed against the commutator hook, wherein the pair of electrodes are pressed independently with a small distance between each other against a shank of the commutator hook, and wherein an electric current is passed through the commutator hook via the pair electrodes to melt the solder and form a connection to the wire winding.

26. An electric machine, comprising:

a commutator connected with at least one wire winding by at least one commutator hook, wherein a solder that connects the wire winding with the commutator is arranged between the wire winding and the at least one commutator hook and a counter surface; and

27. The electric machine of claim 26, wherein the commutator hook comprises, at an outer circumferential area, at least one of:

a bead; and

a heel that spans in a circumferential direction.

28. The electric machine of claim 26, wherein one or more wire windings are arranged between the at least one commutator hook and the counter surface that span over an armature lamellae stack.