Methods and apparatus for commutator fusing
First Claim
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1. A machine for fusing electric motor armatures, each armature comprising a shaft and a commutator, the commutators having commutator bars with top surfaces to which coil leads are connected, the fusing machine comprising:
- a primary electrode;
displacement sensor means for monitoring the displacement between said primary electrode and said shaft;
control means for controlling the displacement of said primary electrode relative to said shaft; and
means for applying force and heat to portions of the commutator bars with the primary electrode to compress the portions of the commutator bars onto the coil leads to form fused lead connections, wherein said control mean directs said means for applying force and heat to compress diametrically opposed portions of the commutator bars with said primary electrode toward common radial positions with respect to the shaft to balance the commutator.
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Abstract
An improved fusing machine is provided that allows commutators to be balanced during the fusing process. Commutator tangs are compressed onto coil leads to form lead connections. The fusing machine compresses the tangs to varying degrees relative to the shaft. The commutator can be balanced during fusing by compressing tangs to a common radial position or by compressing diametrically opposed tangs to the same extent.
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Citations
31 Claims
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1. A machine for fusing electric motor armatures, each armature comprising a shaft and a commutator, the commutators having commutator bars with top surfaces to which coil leads are connected, the fusing machine comprising:
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a primary electrode; displacement sensor means for monitoring the displacement between said primary electrode and said shaft; control means for controlling the displacement of said primary electrode relative to said shaft; and means for applying force and heat to portions of the commutator bars with the primary electrode to compress the portions of the commutator bars onto the coil leads to form fused lead connections, wherein said control mean directs said means for applying force and heat to compress diametrically opposed portions of the commutator bars with said primary electrode toward common radial positions with respect to the shaft to balance the commutator. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A machine for fusing electric motor armatures, each armature comprising a shaft and a commutator, the commutators having commutator bars with top surfaces to which coil leads are connected the fusing machine comprising:
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a primary electrode for compressing portions of the commutator bars onto the coil leads to form lead connections; means for measuring the relative displacement between the shaft and the top surface of each commutator bar; means for comparing the measured relative displacements between the shaft and each bar with a nominal bar height; and means for driving the primary electrode toward the shaft, such that the portions of those commutator bars that have relative displacements greater than the nominal bar height are compressed more than the portions of those commutator bars that have relative displacements less than the nominal bar height, so as to balance the commutator. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A method for fusing electric motor armature lead connections with a fusing machine having a primary electrode, the armatures each comprising a shaft and a commutator, the commutator having bars having portions to which coil leads are connected, the method comprising the step of:
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measuring the displacement between said primary electrode and said shaft; controlling the displacement of said primary electrode relative to said shaft; applying force and heat to the portions of the commutator bars with the primary electrode to to form fused lead connections; and compressing diametrically opposed portions of the commutator bars toward common radial positions with respect to the shaft to balance the commutator. - View Dependent Claims (18, 19, 20, 21, 22, 23)
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24. A method for fusing electric motor armature lead connections, the armatures each comprising a shaft and a commutator, the commutator having commutator bars with top surfaces to which coil leads are connected, the method comprising the steps of:
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measuring the relative displacement between the shaft and the top surface of each commutator bar; comparing the measured displacement for each commutator bar with a nominal bar height; driving a primary electrode toward the shaft with a drive unit to form lead connections by compressing a portion of each of the commutator bars onto the coil leads; compressing the portion of those commutator bars that have relative displacements greater than the nominal bar height more than the portions of the commutator bars that have relative displacements less than the nominal bar height; and compressing the portions of those commutator bars that have relative displacements less than the nominal bar height less than the portions of the commutator bars that have relative displacements more than the nominal bar height. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31)
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Specification