METHOD OF MANUFACTURING A ROTOR ASSEMBLY FOR A DYNAMO ELECTRIC MACHINE

• US 3,861,027 A
• Filed: 11/23/1973
• Issued: 01/21/1975
• Est. Priority Date: 11/23/1972
• Status: Expired due to Term

• Current Assignee: Brian Robert Allen
• Original Assignee: Brian Robert Allen
• Inventors: Allen, Brian Robert
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US05/418,217
• Time in Patent Office: 424 Days
• Field of Search: 29/597,598 310/234,235,237 219/78
• US Class Current: 29/597
• CPC Class Codes: H01R 39/32 Connections of conductor to commutator segment
• CPC Class Codes: H01R 43/08 in which segments are not separated until after assembly
• CPC Class Codes: H02K 15/00 Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly

Abstract

This invention relates to a method of manufacturing a rotor assembly for a dynamo electric machine. The method comprises the steps of stamping an annular conductive disc to produce in one face thereof a plurality of angularly spaced, generally radial grooves having a depth greater than the thickness of the disc so that corresponding ribs are formed on the other face of the disc, moulding an insulating body on said one face of the disc so that the grooves are filled with insulating material, forming a slot in each of the conductive segments defined between pairs of adjacent grooves, engaging one end of at least one of a respective pair of rotor windings of the dynamo electric machine in each of the slots in the conductive segments, resistance joining the ends of the rotor windings received in the slots of at least two conductive segments to their respective segments by engaging an electrode with each of said segments and/or at least one of the windings in each of said slots and passing an electric current between the electrodes through the windings, the segments and the respective rib or ribs defined between the segments, and machining said other face of the disc to remove the ribs and thereby separate the conductive segments from one another.

Claims

1. A method of manufacturing a rotor assembly for a dynamo electric machine comprising the steps of:

a. stamping an annular conductive disc to produce in one face thereof a plurality of angularly spaced, generally radial grooves which divide the disc into conductive segments and which have a depth greater than the thickness of the disc so that corresponding ribs are formed on the other face of the disc, b. moulding an insulating body on said one face of the disc so that the grooves are filled with insulating material, c. forming a slot in each of the conductive segments defined between pairs of adjacent grooves, d. engaging one end of at least one of a respective pair of rotor windings of the dynamo electric machine in each of the slots in the conductive segments, e. resistance joining the ends of the rotor windings received in the slots of at least two conductive segments to their respectivE segements by using at least two electrodes to pass an electric current through the windings, the segments and the at least one rib defined between the segments, each electrode engaging at least one of the components defined by one of said segments and the windings associated with said one segment, and f. machining said other face of the disc to remove said ribs and thereby separate the conductive segments from one another.

2. A method as claimed in claim 1 wherein when the electrodes contact the conductive segments without contacting at least one of the windings in each of the slots, the windings are located against movement in the slots prior to the resistance joining operation.

3. A method as claimed in claim 2 wherein the windings are located against movement in the slots by deformation of the walls of the slots to key the windings in position.

4. A method as claimed in claim 1 wherein step (b) is performed before steps (c), (d), (e) and (f).

5. A method as claimed in claim 1 wherein step (b) is performed after steps (c), (d) and (e) but before step (f).

6. A method as claimed in any claim 1 wherein the resistance joining operation is performed successively for each set of at least two conductive segments.

7. A method as claimed in claim 1 wherein the resistance joining operation is performed simultaneously for all the segments.