Method and device for attaching an electrical wire winding to a commutator

• US 8,294,327 B2
• Filed: 09/17/2007
• Issued: 10/23/2012
• Est. Priority Date: 09/29/2006
• Status: Expired due to Fees

• Current Assignee: Robert Bosch GmbH
• Original Assignee: Robert Bosch GmbH
• Inventors: Chaumet, Pascal, Diederichs, Axel, Neubauer, Achim, Friedmann, Andreas, Altmeyer, Dirk, Huber, Helmut, Herm, Werner, Seiler-Wegner, Edgar
• Primary Examiner(s): LEUNG, QUYEN PHAN
• Assistant Examiner(s): Quinones, Jose Gonzalez
• Application Number:
  US12/440,206
• Publication Number:
  US 20100295409A1
• Time in Patent Office: 1,863 Days
• Field of Search: 310/233, 310/234, 219/85.22, 295/97
• 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. A method of producing an electric motor with a commutator, wherein the commutator comprises at least one commutator hook for mounting 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 and angled to each other against the at least one commutator hook;

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

pressing a free shank of the at least one commutator hook about a bending area formed at a mating surface against the mating surface with the pair of the electrodes, wherein the at least one wire winding is positioned between the free shank and the mating surface; and

;

mechanically pressing the free shank with the pair of the electrodes in a direction of the mating surface prior to passing the electric current through the at least one commutator hook.

2. The method of claim 1, further comprising passing the electric current through the at least one commutator hook until an insulation of the wire winding evaporates and the free shank is hot-pressed.

3. The method of claim 1, further comprising pressing the pair of the electrodes against the at least one commutator hook after turning off the electric current in order to conduct heat away from the at least one commutator hook into the pair of the electrodes.

4. The method of claim 1, wherein the pair of the electrodes lie on the at least one commutator hook a distance of between 0.5 mm to 3 mm, and wherein the pair of the electrodes span over an entire circumferential area of the at least one commutator hook.

5. The method of claim 1, further comprising forming the solder from at least one of silver and tin, wherein the solder melts or at least partially alloys at a temperature between 200°

C. and 300°

C.

6. The method of claim 1, further comprising coating at least one of the at least one commutator hook and the mating surface with solder prior to inserting the wire wiring into the at least one commutator hook.

7. The method of claim 1, further comprising forming the at least one commutator hook and the mating surface from copper, wherein the copper does not melt during the passing of the electric current.

8. The method of claim 1, further comprising forming the counter mating surface as a part of a cylinder jacket that includes a radial projection, wherein the radial projection is a support for a carbon-running surface that interacts with a wiper contact of the electric motor.

15. The method of claim 1, wherein the pressing of one of the pair of the electrodes is done independently of the pressing of another of the pair of the electrodes.

9. A device for connecting a wire winding with a commutator hook of a commutator, the device 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 angled to each other and are pressed against the commutator hook, wherein the pair of the 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 of the electrodes to melt the solder and form a connection to the wire winding.

10. An electric motor 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 hook is arranged between the wire winding and the at least one commutator hook and a mating surface; and

wherein the at least one commutator hook is formed compactly around the wire winding by a pair of electrodes that are arranged adjacent to each other and angled to each other and are pressed against the commutator hook.

11. The electric machine of claim 10, wherein the commutator hook comprises, at an outer circumferential area of the commutator hook, at least one of a bead and a heel that spans in a circumferential direction.

12. The electric machine of claim 10, wherein one or more of the wire windings are arranged between the at least one commutator hook and the mating surface that span over an armature lamellae stack.

13. The electric motor of claim 10, wherein an axial construction length of the commutator is compactly formed by the pair of the electrodes.

14. The electric motor of claim 10, wherein pressing one of the pair of the electrodes is done independently of pressing another of the pair of the electrodes.