Dynamic weld power termination for hot-staking armature commutators
First Claim
1. A method for controlling a hot staking device comprising the steps of:
- (a) bringing an electrode into contact with an armature conductor;
(b) applying a force to the armature conductor with the electrode;
(c) delivering current to the electrode;
(d) terminating the electric current to the electrode after a threshold displacement has been reached; and
(e) continuing to apply the force to the armature conductor with the electrode after terminating the electric current until a maximum weld time has been reached.
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Accused Products
Abstract
The method of the present invention involves setting a penetration threshold as well as a maximum weld time when hot staking armature conductors to the slots of a commutator. To perform each weld, an electrode is forcibly contacted with the top conductor in one of the slots of the commutator. Next, electric current is delivered to the electrode, causing the conductor to heat and begin to deform within the slot. During this time, the electrode moves further into the slot. If the electrode reaches the penetration threshold in the commutator slot before the maximum weld time is reached, current to the electrode is terminated. After terminating current to the electrode, the electrode remains in contact with and applies force to the conductor until the maximum weld time is reached. After the maximum weld time is reached, the electrode is removed from contact with welded conductor.
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Citations
20 Claims
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1. A method for controlling a hot staking device comprising the steps of:
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(a) bringing an electrode into contact with an armature conductor;
(b) applying a force to the armature conductor with the electrode;
(c) delivering current to the electrode;
(d) terminating the electric current to the electrode after a threshold displacement has been reached; and
(e) continuing to apply the force to the armature conductor with the electrode after terminating the electric current until a maximum weld time has been reached. - View Dependent Claims (2, 3, 4, 5)
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6. A method for controlling a hot staking device comprising the steps of:
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(a) bringing an electrode into contact with an armature conductor;
(b) applying a force to the armature conductor with the electrode;
(c) delivering a current to the electrode;
(d) detecting a displacement of the electrode;
(e) tracking a weld time;
(f) if the displacement of the electrode reaches a threshold displacement before the weld time reaches a maximum weld time, terminating the electric current to the electrode and continuing to apply the force to the armature conductor with the electrode after terminating the electric current until the weld time reaches the maximum weld time; and
(g) if the weld time reaches the maximum weld time before displacement of the electrode reaches the threshold displacement, terminating the electric current to the electrode and sounding an alarm. - View Dependent Claims (7, 8, 9, 10)
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11. A device for welding armature conductors in the slots of a commutator, the device comprising:
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(a) means for bringing an electrode into contact with an armature conductor;
(b) means for applying a force to the armature conductor with the electrode;
(c) means for delivering current to the electrode;
(d) means for terminating the electric current to the electrode after a threshold displacement has been reached; and
(e) means for continuing to apply pressure to the armature conductor with the electrode after terminating electric current until a maximum weld time has been reached. - View Dependent Claims (12, 13, 14, 15)
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16. A device for welding an armature conductor in the slot of a commutator, the device comprising:
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(a) a cradle for rotatably supporting the commutator;
(b) a moveable electrode operable to contact the armature conductor in the slot of the commutator supported by the cradle;
(c) a compressor operable to force the electrode against the armature conductor;
(d) a current source for delivering current to the electrode;
(e) a sensor for determining a threshold displacement of the electrode;
(f) a microprocessor operable to (i) instruct the compressor to force the electrode against the armature conductor;
(ii) instruct the current source to deliver current to the electrode after the compressor forces the electrode against the armature conductor;
(iii) receive a signal from the sensor when the electrode reaches the threshold displacement;
(iv) instruct the current source to cease current delivery to the electrode after the electrode reaches the threshold displacement;
(v) determine a total weld time; and
(vi) instruct the compressor to remove the electrode from the armature conductor when the total weld time is greater than or equal to a maximum weld time. - View Dependent Claims (17, 18, 19, 20)
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Specification