Methods and apparatus for fusing electrical conductors
First Claim
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1. Apparatus for fusing at least one armature wire and at least one piece of commutator material together, said apparatus, comprising:
- a fusing member for applying force and varying heat to soften said commutator material to deform said commutator around said armature wire;
a grounding member;
means for moving said fusing member relative to said armature wire and said commutator material in order to cause said fusing member to contact and apply force to said commutator material thereby deforming said commutator material intimately around said armature wire;
means for controlling said means for moving said fusing member in accordance with a predetermined physical delivery function to control said applied force;
means for regulating a precise flow of current through said armature wire and said commutator material from said fusing member to said grounding member to generate said varying heat in said fusing member in accordance with a predetermined electrical delivery function to regulate said precise flow of current and thereby regulate the level of said varying heat so that said commutator material is softened and therefore, said deforming is precisely controlled, and so that insulation on a portion of said armature wire within said softened deformed commutator material is vaporized; and
means for synchronizing said means for controlling and said means for regulating in order to supply a precise varying level and quantity of heat from said fusing member to said armature wire and said commutator material at specific, predetermined time intervals, such that said regulating means is essentially instantaneously responsive to the short timings and different heating requirements which occur during fusing of said armature wire to said commutator material.
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Abstract
Methods and apparatus for fusing together electrical conductors to a commutator are provided. A precise, timed, and controlled delivery of electric current to the fusing electrode of the fusing machine is achieved. A generic supply signal is converted into a precise and constant input signal through the use of monitoring and feedback techniques, which compare the current status of the physical and electrical phases of the fusing operation to various predetermined fusing profiles to determine the proper application of current to the fusing electrode.
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Citations
39 Claims
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1. Apparatus for fusing at least one armature wire and at least one piece of commutator material together, said apparatus, comprising:
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a fusing member for applying force and varying heat to soften said commutator material to deform said commutator around said armature wire; a grounding member; means for moving said fusing member relative to said armature wire and said commutator material in order to cause said fusing member to contact and apply force to said commutator material thereby deforming said commutator material intimately around said armature wire; means for controlling said means for moving said fusing member in accordance with a predetermined physical delivery function to control said applied force; means for regulating a precise flow of current through said armature wire and said commutator material from said fusing member to said grounding member to generate said varying heat in said fusing member in accordance with a predetermined electrical delivery function to regulate said precise flow of current and thereby regulate the level of said varying heat so that said commutator material is softened and therefore, said deforming is precisely controlled, and so that insulation on a portion of said armature wire within said softened deformed commutator material is vaporized; and means for synchronizing said means for controlling and said means for regulating in order to supply a precise varying level and quantity of heat from said fusing member to said armature wire and said commutator material at specific, predetermined time intervals, such that said regulating means is essentially instantaneously responsive to the short timings and different heating requirements which occur during fusing of said armature wire to said commutator material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 36, 37)
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22. The method of using a fusing member to use together at least one armature wire and at least one piece of commutator material, the method comprising the steps of:
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moving said fusing member relative to said armature wire and said commutator material in order to cause said fusing member to contact and apply force to said commutator material thereby deforming said commutator material intimately around said armature wire; controlling the movement of said fusing member in accordance with a predetermined physical delivery function to control said applied force; regulating a precise flow of current through said armature wire and said commutator material from said fusing member to a grounding member to generate varying heat in said fusing member in accordance with a predetermined electrical delivery function to regulate said precise flow of current and thereby regulate the level of said varying heat so that said commutator material is softened and therefore, said deforming is precisely controlled, and so that insulation on a portion of said armature wire within said softened deformed commutator material is vaporized; and synchronizing the control of movement of said fusing member and the regulation of said flow of current in order to supply a precise varying level and quantity of heat from said fusing member to said armature wire and said commutator material at specific, predetermined time intervals, such that said step of regulating is essentially instantaneously responsive to the short timings and different heating requirements which occur during fusing of said armature wire to said commutator material. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
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38. Apparatus for fusing at least one stator wire and at least one piece of contact hook material together, said apparatus comprising:
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a fusing member for applying force and varying heat to soften said contact hook material and to deform said contact hook material around said stator wire; a grounding member; means for moving said fusing member relative to said stator wire and said contact hook material in order to cause said fusing member to contact and apply force to said contact hook material thereby deforming said contact hook material intimately around said stator wire; means for controlling said means for moving said fusing member in accordance with a predetermined physical delivery function to control said applied force; means for regulating a precise flow of current through said stator wire and said contact hook material from said fusing member to said grounding member to generate said varying heat in said fusing member in accordance with a predetermined electrical delivery function to regulate said precise flow of current and thereby regulate the level of said varying heat so that said contact hook material is softened and therefore, said deforming is precisely controlled, and so that insulation on a portion of said stator wire within said softened deformed contact hook material is vaporized; and means for synchronizing said means for controlling said means for regulating in order to supply a precise varying level and quantity of heat from said fusing member to said stator wire and said contact hook material at specific, predetermined time intervals, such that said regulating means is essentially instantaneously responsive to the short timings and different heating requirements which occur during fusing of said stator wire to said contact hook material.
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39. The method of using a fusing member to fuse together at least one stator wire and at least one piece of contact hook material, the method comprising the steps of:
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moving said fusing member relative to said stator wire and said contact hook material in order to cause said fusing member to contact and apply force to said contact hook material thereby forming said contact hook material intimately around said stator wire; controlling the movement of said fusing member in accordance with a predetermined physical delivery function to control said applied force; regulating a precise flow of current through said stator wire and said contact hook material from said fusing member to a grounding member to generate varying heat in said fusing member in accordance with a predetermined electrical delivery function to regulate said precise flow of current and thereby regulate the level of said varying heat so that said contact hook material is softened and therefore, said deforming is precisely controlled, and so that insulation on a portion of said stator wire within said softened deformed contact hook material is vaporized; and synchronizing the control of movement of said fusing member and the regulation of said flow of current in order to supply a precise varying level and quantity of heat from said fusing member to said stator wire and said contact hook material at specific, predetermined time intervals, such that said step of regulating is essentially instantaneously responsive to the short timings and different heating requirements which occur during fusing of said stator wire to said contact hook material.
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Specification