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The Commutator Connection - (5
MB) provides a detailed description of the Commutator Fusing process and
the Commutator Brazing process in the English language. Also mentioned is
the difference between fusing and welding, fusing/brazing electrodes and
electrode dressing, as well as quality control methods and SPC for fusing
and brazing.
Chinese Translation
of The Commutator Connection - (2.1 MB) This is a translation of the
above paper in Chinese. The graphics from the original English language
paper were not displayed in the same high resolution. We suggest that you
download both the English and Chinese language versions, so that you can
get a better idea of what the graphics describe.
Below are three charts, in Adobe's Acrobat file format,
which provide commutator slotting and commutator tang dimensions in different
wire dimensioning systems.
An explanation of the commutator
tang and slotting charts for Commutator Fusing that are listed below.
Commutator Tang and Slotting Charts
(232 K) in American Wire Gauge (AWG)
Commutator Tang and Slotting Charts
(328 K) in Metric Wire Size
Commutator Tang and Slotting Charts
(240 K) in the British Standard Wire Gauge (SWG)
The above charts supply data which do not take into account wire insulation,
electrode design, or commutator design, as well as other variables. For
specific commutator - insulation - electrode - wire combinations, please
consult Allem.
Slope Control offers
many advantages when fusing. Up-Slope provides a cushioned heat to properly
seat the fusing electrodes prior to maximum energy being applied. Down-Slope
provides an annealing heat after welding has occurred. This paper describes
both functions for AC and DC fusing.
The Carbon Commutator
- This is a technical paper that discusses DC and/or Universal Motors that
use Commutators that have a brush track that is made of Carbon or Graphite.
This paper does not directly cover Commutator Fusing of armatures with Carbon
Commutators, other than a very brief discussion of the subject. The paper
discusses the history and development of the carbon commutators and motors
that use Carbon Commutators, and the use in the future, of motors with Carbon
Commutators.
Briefly, the advantage of using motors with Carbon Commutators is that they
have an extremely long brush life, so long that the motor's bearings would
fail prior to the commutator or brushes. Because of their long life, these
types of motors could be used to replaced much more expensive induction
motors.
Fusing and SPC describes
some very basic principles of SPC, and Six Sigma that are used to monitor
and possibly control the Fusing process. This paper covers Commutator Fusing,
SN-Fusing and Tang Fusing, The principles described could also apply to
Commutator and Resistance Brazing and possibly Spot Welding.
Commutator Slotting,
Slitting and Undercutting is a technical paper that describes the cutting
of predominately copper that is used in universal or DC electric motor's
commutator. This paper describes three completely different operations that
can be performed to a commutator.
Magnet Wire Bonding
is a technical paper that describes the process of attaching or gluing adhesive
overcoated magnet wire, in the form of a wound coil, to adjacent magnet
wires of the coil, through the use of very fast heating. The film insulated
magnet wire, wound in a coil, armature, stator, etc., has a film overcoat
of heat activated adhesive, which when heated becomes active. This process
can eliminate taping, resin impregnation, lacing, gluing, etc.
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