EP1769567B1 - Method for the production of a planar commutator and conductor blank for a planar commutator - Google Patents

Method for the production of a planar commutator and conductor blank for a planar commutator Download PDF

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Publication number
EP1769567B1
EP1769567B1 EP05770249A EP05770249A EP1769567B1 EP 1769567 B1 EP1769567 B1 EP 1769567B1 EP 05770249 A EP05770249 A EP 05770249A EP 05770249 A EP05770249 A EP 05770249A EP 1769567 B1 EP1769567 B1 EP 1769567B1
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EP
European Patent Office
Prior art keywords
band
edge
section
conductor
segments
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EP05770249A
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German (de)
French (fr)
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EP1769567A1 (en
Inventor
Jose Potocnik
Boris Kogej
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Kolektor Group doo
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Kolektor Group doo
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Priority to PL05770249T priority Critical patent/PL1769567T3/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/06—Manufacture of commutators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/04—Commutators
    • H01R39/06—Commutators other than with external cylindrical contact surface, e.g. flat commutators
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine
    • Y10T29/49011—Commutator or slip ring assembly

Definitions

  • Such a method is used for example for the production of the DE 19956844 A1 as well as the DE 19752626 A1 used known plan commutators.
  • a flat commutator with carbon tread is prepared by the generic method.
  • the conductor blank is thereby provided in each case by extrusion molding a disk punched out of a metal sheet (in particular copper sheet), the later contact tongues of the conductor segments emerging from the center of the disk, the later connection hooks from the edge portion of the disk and the later connection areas from the intermediate ring area the conductor segments.
  • Such prefabricated by extrusion molding forming conductor blanks are also used in the production of plan commutators with carbon surface by other methods, for example, the bridge parts are removed before spraying the carrier body, after previously the conductor blank with the carbon ring was assembled into a composite part (see. DE 4028420 A1 ), or the carbon ring disk is only applied to the already separated conductor segments, after previously the carrier body was molded onto the conductor blank and then the bridge parts were removed (see. WO 97/03486 A1 ).
  • the conductor blank as in the EP 935331 A1 also be made by round bending a punched out of copper sheet strip-shaped blank.
  • the punched-out blank has in this case in the region of its one edge the later connection hooks and in the region of the opposite edge the later contact tongues.
  • the flat commutator produced in accordance with the generic method according to the DE 19956844 A1 meets high requirements.
  • carbon surface plan commutators can be manufactured at a cost which is less than that produced by the prior art planar commutators having substantially the same characteristics.
  • two factors of influence come into play. Firstly, the degree of utilization of the starting material is higher than in the prior art in application of the method according to the invention; the accordingly reduced waste has a corresponding cost-reducing effect.
  • the method of the invention is without any F technically pre-forming, because a longitudinally pre-profiled strip starting material for the production of the conductor blank is used, because the wall thickness of the bridge parts is the same as the wall thickness of the terminal portions of the conductor segments and because the reeds to a To ensure optimal connection to the carbon segments and with the carrier body, profiled at their axial end faces solely by axial shear.
  • profiling of the contact tongues is on the pending German patent application 10359473.6 the assignee of the present patent application.
  • the invention provided according to the present invention on the first side of the band in the second edge portion third stage causes the contact tongues have a greater wall thickness at the end than at transition areas, by means of which they are connected to the terminal areas. This is advantageous with regard to a long-lasting connection of the carbon segments with the contact regions of the conductor segments; and the end-increased material thickness of the contact tongues allows to introduce a pronounced profiling there by means of the already described shear.
  • the bridge parts are completely removed by twisting in a single operation. This is made possible in that the connection hooks of the commutator blank are aligned in the axial direction, so that they do not hinder the twisting of the bridge parts. In the prior art, in contrast, due to the radially aligned from the beginning connecting hook a complete twisting the bridge parts in a single operation is not possible.
  • the invention allows several possibilities.
  • first the section of the metallic strip is cut to length from a supply, before subsequently the two edge sections of the strip are punched out to form the connection hooks in the first edge section and the contact tongues in the second edge section.
  • the section of the metallic strip is cut to length after the two edge sections of the strip have previously been punched out to form the connection hooks in the first edge section and the contact tongues in the second edge section.
  • the section of the metallic strip is cut to length and the two edge sections of the strip are punched out to form the connection hooks and the contact tongues.
  • the invention allows several possibilities.
  • the section of the band is first rolled to form a closed ring structure, before the corrugation is subsequently introduced into the section of the band;
  • this is supported radially in particular in the area of the bridge parts, while the conductor segments are displaced radially inwardly by corresponding radial punches until they rest against a correspondingly profiled inner tool.
  • the second variant of the method provides for the section of the strip to be rolled to form a closed ring structure, after the corrugation has previously been introduced into the section of the strip, in particular in a stamping press. And here is also considered, according to a third variant of the method, the section of the tape, after previously the contour has been punched, to roll in a single step to form a closed ring structure and at the same time introduce the corrugation.
  • introducing the corrugation is preferably carried out also a slight deformation of the areas between the waves, ie the first flat terminal portions of the conductor segments, so that they are slightly curved; this helps minimize the required machining finish of the commutator blank.
  • the contact tongues are bent in two steps inwards in the direction of the axis, wherein the second step is a calibration step.
  • the conductor blank is to be manufactured with particularly low tolerances in order to be able to be joined together with the carbon ring disk to form reliably electrically conductive connections.
  • this applies in the case of a positive engagement of the profiled contact tongues of the conductor segments in correspondingly profiled recordings of the carbon ring disc.
  • Anchor parts as they are to be arranged on the radial inner side of the conductor segments to be embedded in the molding material during injection of the carrier body and there to anchor the conductor segments are preferred in the context of the inventive method by axial splitting of the radial inner surfaces of the terminal regions of the conductor segments produced.
  • Two anchor parts are preferably split off from the respective connection region per conductor segment, specifically after the introduction of the corrugation.
  • the punching of the contact tongues extends only in the second edge portion of the band.
  • the second stage is circumferentially closed as a sealing surface for sealing the injection mold available.
  • the punch-out preferably extends from the first edge beyond the first step into the main portion of the band.
  • the corresponding punching of the connection hooks in the region of the main section is particularly preferably limited by conical edges against which the injection molding tool bears in a sealing manner.
  • Such a conductor blank can be seen with advantage not only in the method described above. Rather, it can be used with matching advantages even in modified processes with a modified sequence of manufacturing steps.
  • the surface of the conductor blank as a whole is silvered or tinned, at least in the regions of the contact tongues provided for contact with the carbon segments, which later are made of the carbon ring disk.
  • edge in the context of the present application is to be understood that it defines only in the case of a physical edge of the strip-shaped tape, that as a starting material a metallic strip sheet is used with such a width that not several punch out adjacent sections of tape. If, on the other hand, the latter is the case, the term "edge" indicates a fictitious limitation of the relevant section from the starting material used to produce the respective strip section.
  • the in Fig. 1 illustrated annular closed conductor blank 1 comprises eight evenly around the axis 2 arranged around conductor segments 3 and eight bridge parts 4, which each connect two adjacent conductor segments 3 together.
  • Each conductor segment has, on the one hand, a substantially axially aligned connection region 5 with a likewise axially aligned connection hook 6 and, on the other hand, a substantially radially inwardly aligned contact tongue 7.
  • the bridge parts 4 project in waveform radially outward beyond the terminal portions 5 of the conductor segments 3.
  • Their wall thickness D 1 corresponds to the wall thickness D 2 of the terminal portions 5 of the conductor segments 3. The waves rise so far that the maximum distance of its inner wall from the axis 2 is greater than the distance of the outer wall of the terminal portions 5 of the axis. 2
  • the conductor blank has emerged from a series of simple forming steps from a metallic longitudinal strip 8 with the in Fig. 2 cross section shown.
  • the band 8 has on its one, first side 9, which represents the later radial inner surface, a first step 10, which forms an increase in material thickness from the first edge 11 of the band 8 adjacent to this step.
  • the first stage 10 and the second stage 13 keep a distance A from one another.
  • the region of the band 8 lying between the first step 10 and the second step 13 forms its main section H.
  • the region of the band 8 lying between the first edge 11 and the first step 10 forms its first edge section 17 and that between the second edge 14 and the second stage 13 lying portion of the belt 8 forms the second edge portion 18th
  • the band 8 also has a third step 15 in the second edge section 18 on the first side 9. At the third stage 15, the material thickness increases in the direction of the second edge 14.
  • the conductor blank 1 For the preparation of the conductor blank 1 is first in a first step of a supply of longitudinally profiled metal strip ( Fig. 3 ) punched out a section 16. At the same time, the connection hooks 6 in the first edge section 17, the contact tongues 7 in the second edge section 18 and partly the main section H and the end regions are punched out with two mutually corresponding engagement sections 19 and 20 of a dovetail-shaped lock 21. Then, the band portion 16 is rolled to form a closed ring structure, wherein the shock-locking lock 21 is closed.
  • the corrugation is introduced into the annularly closed band section 16 by-in a corresponding tool-the conductor segments 3 are displaced radially inwards by corresponding radial punches, while a profiled inner tool supports the bridge parts 4 from radially inward.
  • the contact tongues 7 are bent inwards in the direction of the axis 2 in two steps.
  • the contact areas are then profiled by an axial shear in mutually corresponding upper and lower tools, before finally 3 armature parts 22 are produced by a gap step at the radial inner surfaces of the terminal portions 5 of the conductor segments.
  • the conductor blank 1 produced in this way is produced in a substantially known process (cf. DE 19956844 A1 ) for producing a flat commutator 23 with carbon brush surface 24 further processed.
  • a carbon ring disk is joined together with the conductor blank 1 to form a composite part to produce electrically conductive connections between the contact tongues 7 of the conductor segments 3 and the carbon ring disk.
  • the composite part is then placed in an open injection mold. The injection mold is closed.
  • a first part tool is located on a first sealing surface formed by the first step 10, the side faces 25 of the conical foot sections 26 of the connection hooks 6 and the associated end faces 27 of the bridge parts 4; and a second part tool abuts against a second sealing surface formed by the second step 13 and the associated end faces of the bridge parts 4.
  • the carrier body 28 is molded by injecting plasticized molding material into the injection mold. After the molding material has cured, the injection mold is opened and the resulting commutator blank from the Removed injection mold. Finally, the bridging parts 4 are removed by twisting, and the carbon ring disc is divided by cuts into individual carbon segments 29.
  • the strip 8 has on its second side 12 in the region of the main section H a fourth step 30 at which the material thickness in the direction of the first edge 11 points decreases.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Motor Or Generator Current Collectors (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
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Abstract

The invention relates to the production of a planar commutator with a carbon running surface, wherein an annular closed corrugated conductor blank ( 1 ), comprising conductor segments ( 3 ) and bridging parts ( 4 ) connecting said bridging segments to each other, is produced by rolling from a longitudinal-stepped profiled strip section which is stamped on the edges thereof in order to create contact studs ( 7 ) and connection hooks ( 6 ). After the band section has been rolled, the contact studs ( 7 ) of the conductor segments are bent inwards in the direction of the axis ( 2 ) and are profiled on both axial front surfaces by means of a shearing process. The conductor blank is assembled with an annular carbon disk to form a composite part onto which a support element is molded by injection. The annular carbon disk is then subdivided into individual carbon segments and the bridging parts are removed or severed.

Description

Die vorliegende Erfindung betrifft, wie im Oberbegriff des Anspruchs 1 angegeben, ein Verfahren zur Herstellung eines Plankommutators, welcher einen aus Preßstoff gefertigten Trägerkörper, eine Mehrzahl von gleichmäßig um eine Achse herum angeordneten, in dem Trägerkörper verankerten Leitersegmenten und eine ebenso große Anzahl von mit diesen elektrisch leitend verbundenen, die Bürstenlauffläche definierenden Kohlenstoffsegmenten aufweist, mit den folgenden Schritten:

  • Bereitstellen eines ringförmig geschlossenen Leiterrohlings mit Leitersegmenten und jeweils zwei benachbarte Leitersegmente miteinander verbindenden Brückenteilen, wobei die Leitersegmente im wesentlichen axial ausgerichtete Anschlußbereiche mit jeweils einem Anschlußhaken und im wesentlichen radial ausgerichtete Kontaktzungen aufweisen;
  • Bereitstellen einer Kohlenstoffringscheibe;
  • Zusammenfügen der Kohlenstoffringscheibe und des Leiterrohlings zu einem Verbundteil unter Herstellung elektrisch leitender Verbindungen zwischen den Kontaktzungen der Leitersegmente und der Kohlenstoffringscheibe;
  • Einlegen des Verbundteils in ein geöffnetes Spritzgießwerkzeug;
  • Schließen des Spritzgießwerkzeugs;
  • Formen des Trägerkörpers durch Einspritzen von plastifiziertem Preßstoff in das Spritzgießwerkzeug;
  • Entnehmen des Kommutatorrohlings aus dem Spritzgießwerkzeug;
  • Unterteilen der Kohlenstoffringscheibe in einzelne Segmente sowie Entfernen oder Durchtrennen der Brückenteile.
The present invention relates, as indicated in the preamble of claim 1, a method for producing a Plankommutators, which is made of a pressed material carrier body, a plurality of uniformly arranged around an axis around, anchored in the carrier body conductor segments and an equally large number of these electrically conductive connected, the brush tread defining carbon segments, comprising the following steps:
  • Providing a ring-shaped closed conductor blank with conductor segments and each two adjacent conductor segments interconnecting bridge parts, wherein the conductor segments have substantially axially aligned terminal portions each having a connection hook and substantially radially aligned contact tongues;
  • Providing a carbon ring disk;
  • Assembling the carbon ring disk and the conductor blank into a composite part to make electrically conductive connections between the contact tongues of the conductor segments and the carbon ring disk;
  • Inserting the composite part into an opened injection mold;
  • Closing the injection mold;
  • Molding the carrier body by injecting plasticized molding material into the injection mold;
  • Removing the commutator blank from the injection mold;
  • Dividing the carbon ring into individual segments and removing or cutting through the bridge parts.

Ein solches Verfahren wird beispielsweise zur Herstellung der aus der DE 19956844 A1 sowie der DE 19752626 A1 bekannten Plankommutatoren eingesetzt. Auch gemäß der älteren, aber nachveröffentlichten DE 10359473 A1 wird ein Plankommutator mit Kohlenstofflauffläche nach dem gattungsgemäßen Verfahren hergestellt. Bereitgestellt wird der Leiterrohling dabei jeweils durch Fließpreß-Umformen einer aus einem Metallblech (insbesondere Kupferblech) ausgestanzten Scheibe, wobei aus dem Zentrum der Scheibe die späteren Kontaktzungen der Leitersegmente hervorgehen, aus dem Randabschnitt der Scheibe die späteren Anschlußhaken und aus dem dazwischenliegenden Ringbereich die späteren Anschlußbereiche der Leitersegmente.Such a method is used for example for the production of the DE 19956844 A1 as well as the DE 19752626 A1 used known plan commutators. Also according to the older, but post-published DE 10359473 A1 a flat commutator with carbon tread is prepared by the generic method. The conductor blank is thereby provided in each case by extrusion molding a disk punched out of a metal sheet (in particular copper sheet), the later contact tongues of the conductor segments emerging from the center of the disk, the later connection hooks from the edge portion of the disk and the later connection areas from the intermediate ring area the conductor segments.

Solche durch Fließpreß-Umformen vorgefertigte Leiterrohlinge werden auch bei der Herstellung von Plankommutatoren mit Kohlenstoffläuffläche nach anderen Verfahren eingesetzt, wobei beispielsweise die Brückenteile bereits vor dem Spritzen des Trägerkörpers entfernt werden, nachdem zuvor der Leiterrohling mit der Kohlenstoffringscheibe zu einem Verbundteil zusammengefügt wurde (vgl. DE 4028420 A1 ), oder aber die Kohlenstoffringscheibe erst auf die bereits voneinander getrennten Leitersegmente aufgebracht wird, nachdem zuvor der Trägerkörper an den Leiterrohling angespritzt wurde und anschließend die Brückenteile entfernt wurden (vgl. WO 97/03486 A1 ).Such prefabricated by extrusion molding forming conductor blanks are also used in the production of plan commutators with carbon surface by other methods, for example, the bridge parts are removed before spraying the carrier body, after previously the conductor blank with the carbon ring was assembled into a composite part (see. DE 4028420 A1 ), or the carbon ring disk is only applied to the already separated conductor segments, after previously the carrier body was molded onto the conductor blank and then the bridge parts were removed (see. WO 97/03486 A1 ).

Statt durch Fließpress-Umformung aus einer ausgestanzten Scheibe kann der Leiterrohling, wie in der EP 935331 A1 offenbart, auch durch Rundbiegen eines aus Kupferblech ausgestanzten streifenförmigen Zuschnitts hergestellt werden. Der ausgestanzte Zuschnitt weist dabei im Bereich seines einen Randes die späteren Anschlusshaken und im Bereich des gegenüberliegenden Randes die späteren Kontaktzungen auf. Nach dem Rundbiegen des streifenförmigen Zuschnitts werden die Anschlusshaken nach außen und die Kontaktzungen nach innen gebogen, bevor sodann die Kohlenstoffringscheibe an den Kontaktzungen angelötet, der Trägerkörper gespritzt und die Kohlenstoffringscheibe und der Leiterrohling durch Trennschnitte in einzelne Segmente unterteilt werden.Instead of extrusion molding from a punched disc, the conductor blank, as in the EP 935331 A1 also be made by round bending a punched out of copper sheet strip-shaped blank. The punched-out blank has in this case in the region of its one edge the later connection hooks and in the region of the opposite edge the later contact tongues. After the round bending of the strip-shaped blank the connection hooks bent outwards and the contact tongues inwards, before then the carbon ring washer is soldered to the contact tongues, the carrier body is sprayed and the carbon ring disk and the conductor blank are divided into individual segments by separating cuts.

Insbesondere der in Anwendung des gattungsgemäßen Verfahrens hergestellte Plankommutator gemäß der DE 19956844 A1 genügt hohen Anforderungen. Indessen wird vor dem Hintergrund des allgemeinen Kostendrucks angestrebt, einen Plankommutator mit denselben günstigen Eigenschaften (Langlebigkeit und hohe Zuverlässigkeit), wie sie dieser Plankommutator aufweist, zu geringeren Herstellungskosten fertigen zu können.In particular, the flat commutator produced in accordance with the generic method according to the DE 19956844 A1 meets high requirements. However, against the background of general cost pressure, it is desirable to be able to produce a flat commutator with the same favorable properties (longevity and high reliability) as that flat commutator, at lower production costs.

Gelöst wird diese Zielsetzung gemäß der vorliegenden Erfindung, indem sich bei einem gattungsgemäßen Verfahren zur Herstellung eines Plankommutators die Vorfertigung des Leiterrohlings durch die folgende Merkmale auszeichnet:

  • Bereitstellen eines metallischen längsstufenförmigen Bandes, das durch einen ersten Rand und einen hierzu parallelen zweiten Rand begrenzt ist, wobei das Band einen Hauptabschnitt, welcher durch eine auf der einen, ersten Seite des Bandes benachbart zu dem ersten Rand angeordnete erste Stufe und eine auf der anderen, zweiten Seite des Bandes benachbart zu dem zweiten Rand angeordnete zweite Stufe begrenzt ist, einen zwischen dem ersten Rand und der ersten Stufe angeordneten ersten Randabschnitt und einen zwischen dem zweiten Rand und der zweiten Stufe angeordneten zweiten Randabschnitt aufweist und die Materialstärke des Bandes an der ersten und der zweiten Stufe jeweils vom Hauptabschnitt zum entsprechenden Randabschnitt hin abnimmt, und wobei ferner das Band auf seiner ersten Seite im Bereich des zweiten Randabschnitts eine dritte Stufe aufweist, an der die Materialstärke in Richtung auf den zweiten Rand zunimmt;
  • Ablängen eines Abschnitts des metallischen Bandes und Ausstanzen der beiden Randabschnitte des Bandes zur Bildung der Anschlußhaken in dem ersten Randabschnitt und der Kontaktzungen in dem zweiten Randabschnitt;
  • Rollieren des Bandabschnitts zur Bildung einer geschlossenen Ringstruktur und Einbringen einer Wellung in den Hauptabschnitt mit im Bereich der Brückenteile vorspringenden Wellen, wobei die Ringstruktur im Bereich der Wellen im wesentlichen dieselbe Wandstärke aufweist wie zwischen den Wellen;
  • Biegen der Kontaktzungen einwärts in Richtung auf die Achse;
  • Profilieren der Kontaktzungen auf beiden axialen Stirnflächen durch einen Scherprozeß in axialer Richtung.
This object is achieved according to the present invention by the prefabrication of the conductor blank is characterized by the following features in a generic method for producing a flat commutator:
  • Providing a metallic elongated strip bounded by a first edge and a second edge parallel thereto, the strip having a major portion extending through a first stage disposed on one, first side of the band adjacent to the first edge and one on top of the other , Second side of the band adjacent to the second edge disposed second stage, having a first edge disposed between the first edge and the first stage first edge portion and disposed between the second edge and the second stage second edge portion and the material thickness of the strip at the first and the second stage respectively decreases from the main portion to the corresponding edge portion, and further wherein the band has on its first side in the region of the second edge portion a third stage at which the material thickness increases in the direction of the second edge;
  • Cutting a portion of the metallic strip and punching the two edge portions of the strip to form the terminal hooks in the first edge portion and the contact tongues in the second edge portion;
  • Rolling of the band portion to form a closed ring structure and introducing a corrugation in the main portion with projecting in the region of the bridge parts waves, the ring structure in the region of the waves having substantially the same wall thickness as between the waves;
  • Bending the tabs inwardly toward the axis;
  • Profiling the contact tongues on both axial faces by a shearing process in the axial direction.

In Anwendung eines durch die Kombination dieser Merkmale gekennzeichneten Verfahrens lassen sich Plankommutatoren mit Kohlenstofflauffläche zu Kosten herstellen, die unter denjenigen liegen, wie sie bei der Herstellung von Plankommutatoren mit im wesentlichen gleicher Charakteristik nach dem Stand der Technik entstehen. In diesem Zusammenhang kommen insbesondere zwei Einflußfaktoren zum Tragen. Zum einen ist in Anwendung des erfindungsgemäßen Verfahrens der Grad der Ausnutzung des Ausgangsmaterials höher als nach dem Stand der Technik; der demgemäß reduzierte Verschnitt wirkt sich entsprechend kostensenkend aus. Und des weiteren kommt das erfindungsgemäße Verfahren ohne jegliches Fließpreß-Umformen aus, weil ein längstufenförmig vorprofiliertes Band-Ausgangsmaterial für die Herstellung des Leiterrohlings eingesetzt wird, weil die Wandstärke der Brückenteile dieselbe ist wie die Wandstärke der Anschlußbereiche der Leitersegmente und weil die Kontaktzungen, um eine optimale Verbindung zu den Kohlenstoffsegmenten und mit dem Trägerkörper zu gewährleisten, an ihren axialen Stirnflächen allein durch eine axiale Scherung profiliert werden. Indem auf jegliche Fließpreß-Umformung verzichtet werden kann, ist der technische Aufwand für die Durchführung des erfindungsgemäßen Verfahrens entsprechend reduziert; so kann in Anwendung der vorliegenden Erfindung insbesondere auf jegliches Weichglühen des Materials im Rahmen des Herstellungsprozesses verzichtet werden. Die dementsprechend, verglichen mit dem Stand der Technik, erhöhte Wandstärke der Brückenteile erweist sich im übrigen als günstig für deren axiale Tragfähigkeit, so daß das zum Einspritzen des Trägerkörpers verwendete Spritzgießwerkzeug, ohne daß die Gefahr einer Beschädigung der eingelegten Leiterrohlinge besteht, selbst dann mit entsprechend hohen Schließkräften beaufschlagt werden kann, wenn die jeweils zwischen zwei einander benachbarten Brückenteilen bestehenden Dichtflächen vergleichsweise schmal sind. In diesem Zusammenhang spielt eine Rolle, daß zum Abdichten des Spritzgießwerkzeugs an dem Leiterrohling an der den Kontaktzungen gegenüberliegenden Seite im Bereich der axial ausgerichteten Anschlußhaken (nur) die erste Stufe zur Verfügung steht, so daß der überwiegende Anteil der Schließkraft über die Brückenteile abzutragen ist.Using a method characterized by the combination of these features, carbon surface plan commutators can be manufactured at a cost which is less than that produced by the prior art planar commutators having substantially the same characteristics. In this context, in particular two factors of influence come into play. Firstly, the degree of utilization of the starting material is higher than in the prior art in application of the method according to the invention; the accordingly reduced waste has a corresponding cost-reducing effect. And further, the method of the invention is without any Fließpreß-forming, because a longitudinally pre-profiled strip starting material for the production of the conductor blank is used, because the wall thickness of the bridge parts is the same as the wall thickness of the terminal portions of the conductor segments and because the reeds to a To ensure optimal connection to the carbon segments and with the carrier body, profiled at their axial end faces solely by axial shear. By eliminating any Fließpreß-forming, the technical complexity for the implementation of the method according to the invention is reduced accordingly; Thus, in application of the present invention, in particular all soft annealing of the material in the context of the production process can be dispensed with. The accordingly, compared with the prior art, increased wall thickness of the bridge parts proves to be favorable for the axial load capacity, so that the injection molding tool used for injecting the body, without the risk of damaging the inserted conductor blanks, even then with accordingly high closing forces can be applied when the respectively existing between two adjacent bridge parts sealing surfaces are comparatively narrow. In This connection plays a role that for sealing the injection molding on the conductor blank on the opposite side of the contact tongues in the region of the axially aligned connection hooks (only) the first stage is available, so that the majority of the closing force is removed via the bridge parts.

Im Hinblick auf das für die vorliegende Erfindung wesentliche Profilieren der Kontaktzungen, nachdem diese in ihre im wesentlichen radial nach innen gerichtete Stellung gebogen worden sind, durch eine rein axiale Scherung in zueinander korrespondierenden Ober- und Unterwerkzeugen wird auf die schwebende deutsche Patentanmeldung 10359473.6 der Anmelderin der vorliegenden Patentanmeldung Bezug genommen. Die nach der vorliegenden Erfindung an der ersten Seite des Bandes im zweiten Randabschnitt vorgesehene dritte Stufe bewirkt, daß die Kontaktzungen endseitig eine größere Wandstärke aufweisen als an Übergangsbereichen, mittels derer sie mit den Anschlußbereichen verbunden sind. Dies ist von Vorteil im Hinblick auf eine langlebige Verbindung der Kohlenstoffsegmente mit den Kontaktbereichen der Leitersegmente; und die endseitig vergrößerte Materialstärke der Kontaktzungen gestattet, dort in diese mittels der bereits erläuterten Scherung eine ausgeprägte Profilierung einzubringen.In view of the essential for the present invention profiling of the contact tongues, after they have been bent into their substantially radially inwardly directed position by a purely axial shear in mutually corresponding upper and lower tools is on the pending German patent application 10359473.6 the assignee of the present patent application. The invention provided according to the present invention on the first side of the band in the second edge portion third stage causes the contact tongues have a greater wall thickness at the end than at transition areas, by means of which they are connected to the terminal areas. This is advantageous with regard to a long-lasting connection of the carbon segments with the contact regions of the conductor segments; and the end-increased material thickness of the contact tongues allows to introduce a pronounced profiling there by means of the already described shear.

Gemäß einer ersten bevorzugten Weiterbildung des erfindungsgemäßen Verfahrens ist vorgesehen, daß die Brückenteile in einem einzigen Arbeitsgang durch Abdrehen vollständig entfernt werden. Dies wird ermöglicht dadurch, daß die Anschlußhaken des Kommutatorrohlings in axialer Richtung ausgerichtet sind, so daß sie das Abdrehen der Brückenteile nicht behindern. Beim Stand der Technik ist demgegenüber infolge der von Anbeginn radial ausgerichteten Anschlußhaken ein vollständiges Abdrehen der Brückenteile in einem einzigen Arbeitsgang nicht möglich.According to a first preferred embodiment of the method according to the invention it is provided that the bridge parts are completely removed by twisting in a single operation. This is made possible in that the connection hooks of the commutator blank are aligned in the axial direction, so that they do not hinder the twisting of the bridge parts. In the prior art, in contrast, due to the radially aligned from the beginning connecting hook a complete twisting the bridge parts in a single operation is not possible.

Was die Reihenfolge des Ablängens des Abschnitts des metallischen Bandes einerseits und des Ausstanzens der beiden Randabschnitte des Bandes andererseits angeht, so läßt die Erfindung mehrere Möglichkeiten zu. Gemäß einer ersten Verfahrensvariante wird zuerst der Abschnitt des metallischen Bandes von einem Vorrat abgelängt, bevor anschließend die beiden Randabschnitte des Bandes zur Bildung der Anschlußhaken in dem ersten Randabschnitt und der Kontaktzungen in dem zweiten Randabschnitt ausgestanzt werden. Gemäß einer zweiten Verfahrensvariante ist vorgesehen, daß der Abschnitt des metallischen Bandes abgelängt wird, nachdem zuvor die beiden Randabschnitte des Bandes zur Bildung der Anschlußhaken in dem ersten Randabschnitt und der Kontaktzungen in dem zweiten Randabschnitt ausgestanzt worden sind. Gemäß einer dritten Verfahrensvariante werden gleichzeitig, in demselben Arbeitsschritt, der Abschnitt des metallischen Bandes abgelängt und die beiden Randabschnitte des Bandes zur Bildung der Anschlußhaken und der Kontaktzungen ausgestanzt.As for the order of cutting the portion of the metallic strip on the one hand and the punching of the two edge portions of the band on the other hand, the invention allows several possibilities. According to a first variant of the method, first the section of the metallic strip is cut to length from a supply, before subsequently the two edge sections of the strip are punched out to form the connection hooks in the first edge section and the contact tongues in the second edge section. According to a second variant of the method, it is provided that the section of the metallic strip is cut to length after the two edge sections of the strip have previously been punched out to form the connection hooks in the first edge section and the contact tongues in the second edge section. According to a third variant of the method, at the same time, in the same step, the section of the metallic strip is cut to length and the two edge sections of the strip are punched out to form the connection hooks and the contact tongues.

Auch was die Reihenfolge des Rollierens des Abschnitts des Bandes und des Einbringens der Wellung angeht, läßt die Erfindung mehrere Möglichkeiten zu. Gemäß einer insoweit ersten Verfahrensvariante wird zuerst der Abschnitt des Bandes zur Bildung einer geschlossenen Ringstruktur rolliert, bevor anschließend die Wellung in den Abschnitt des Bandes eingebracht wird; in diesem Falle wird zum Einbringen der Wellung in den bereits ringförmig geschlossenen Abschnitt des Bandes dieses insbesondere im Bereich der Brückenteile radial innen abgestützt, während die Leitersegmente durch entsprechende Radialstempel radial nach innen verschoben werden, bis sie an einem entsprechend profilierten Innenwerkzeug anliegen. Gemäß einer insoweit zweiten Verfahrensvariante ist vorgesehen, daß der Abschnitt des Bandes zur Bildung einer geschlossenen Ringstruktur rolliert wird, nachdem zuvor, insbesondere in einer Gesenkpresse, die Wellung in den Abschnitt des Bandes eingebracht worden ist. Und auch hier kommt in Betracht, gemäß einer dritten Verfahrensvariante den Abschnitt des Bandes, nachdem zuvor die Kontur ausgestanzt worden ist, in einem einzigen Arbeitsschritt zur Bildung einer geschlossenen Ringstruktur zu rollieren und gleichzeitig die Wellung einzubringen. Bei sämtlichen Varianten erfolgt beim Einbringen der Wellung bevorzugt auch ein leichtes Verformen der Bereiche zwischen den Wellen, d.h. der zunächst ebenen Anschlußbereiche der Leitersegmente, so daß diese leicht gewölbt sind; dies trägt dazu bei, die erforderliche spanabhebende Endbearbeitung des Kommutatorrohlings zu minimieren.Also, as regards the order of the curling of the portion of the band and the introduction of the corrugation, the invention allows several possibilities. According to a first variant of the method, the section of the band is first rolled to form a closed ring structure, before the corrugation is subsequently introduced into the section of the band; In this case, for introducing the corrugation into the already annularly closed section of the belt, this is supported radially in particular in the area of the bridge parts, while the conductor segments are displaced radially inwardly by corresponding radial punches until they rest against a correspondingly profiled inner tool. According to one extent The second variant of the method provides for the section of the strip to be rolled to form a closed ring structure, after the corrugation has previously been introduced into the section of the strip, in particular in a stamping press. And here is also considered, according to a third variant of the method, the section of the tape, after previously the contour has been punched, to roll in a single step to form a closed ring structure and at the same time introduce the corrugation. In all variants, when introducing the corrugation is preferably carried out also a slight deformation of the areas between the waves, ie the first flat terminal portions of the conductor segments, so that they are slightly curved; this helps minimize the required machining finish of the commutator blank.

Gemäß einer anderen bevorzugten Weiterbildung des erfindungsgemäßen Verfahrens ist vorgesehen, daß die Kontaktzungen in zwei Schritten einwärts in Richtung auf die Achse gebogen werden, wobei es sich bei dem zweiten Schritt um einen Kalibrierschritt handelt. Dies ist günstig im Hinblick darauf, daß der Leiterrohling mit besonders geringen Toleranzen zu fertigen ist, um mit der Kohlenstoffringscheibe unter Bildung zuverlässig elektrisch leitender Verbindungen zusammengefügt werden zu können. Namentlich gilt dies im Falle eines formschlüssigen Eingriffs der profilierten Kontaktzungen der Leitersegmente in korrespondierend profilierte Aufnahmen der Kohlenstoffringscheibe.According to another preferred embodiment of the method according to the invention it is provided that the contact tongues are bent in two steps inwards in the direction of the axis, wherein the second step is a calibration step. This is favorable in view of the fact that the conductor blank is to be manufactured with particularly low tolerances in order to be able to be joined together with the carbon ring disk to form reliably electrically conductive connections. In particular, this applies in the case of a positive engagement of the profiled contact tongues of the conductor segments in correspondingly profiled recordings of the carbon ring disc.

Ankerteile, wie sie an der radialen Innenseite der Leitersegmente anzuordnen sind, um beim Spritzen des Trägerkörpers in den Preßstoff eingebettet zu werden und dort die Leitersegmente zu verankern, werden im Rahmen des erfindungsgemäßen Verfahrens bevorzugt durch axiales Spalten der radialen Innenflächen der Anschlußbereiche der Leitersegmente hergestellt. Bevorzugt werden dabei pro Leitersegment zwei Ankerteile von dem jeweiligen Anschlußbereich abgespalten, und zwar nach dem Einbringen der Wellung.Anchor parts, as they are to be arranged on the radial inner side of the conductor segments to be embedded in the molding material during injection of the carrier body and there to anchor the conductor segments are preferred in the context of the inventive method by axial splitting of the radial inner surfaces of the terminal regions of the conductor segments produced. Two anchor parts are preferably split off from the respective connection region per conductor segment, specifically after the introduction of the corrugation.

Gemäß einer abermals anderen bevorzugten weiterbildung der Erfindung erstreckt sich die Ausstanzung der Kontaktzungen ausschließlich in dem zweiten Randabschnitt des Bandes. In diesem Falle steht bei dem Leiterrohling die zweite Stufe umlaufend geschlossen als eine Abdichtfläche für eine Abdichtung des Spritzgießwerkzeugs zur Verfügung.According to yet another preferred embodiment of the invention, the punching of the contact tongues extends only in the second edge portion of the band. In this case, in the conductor blank, the second stage is circumferentially closed as a sealing surface for sealing the injection mold available.

Auf der gegenüberliegenden Seite, nämlich im Bereich der Anschlußhaken, erstreckt sich die Ausstanzung indessen bevorzugt von dem ersten Rand her über die erste Stufe hinaus in den Hauptabschnitt des Bandes hinein. Dabei ist die entsprechende Ausstanzung der Anschlußhaken im Bereich des Hauptabschnitts besonders bevorzugt durch konische Kanten begrenzt, an denen das Spritzgießwerkzeug dichtend anliegt.On the opposite side, namely in the region of the connecting hooks, however, the punch-out preferably extends from the first edge beyond the first step into the main portion of the band. In this case, the corresponding punching of the connection hooks in the region of the main section is particularly preferably limited by conical edges against which the injection molding tool bears in a sealing manner.

Aus den vorstehenden Erläuterungen des erfindungsgemäßen Verfahrens läßt sich ableiten, daß ein besonders bevorzugter, zur Verwendung bei einem Verfahren zur Herstellung eines Plankommutators verwendbarer ringförmig geschlossener Leiterrohling eine Mehrzahl von gleichmäßig um eine Achse herum angeordneten Leitersegmenten und jeweils zwei benachbarte Leitersegmente miteinander verbindende Brückenteile umfaßt, wobei die Leitersegmente im wesentlichen axial ausgerichtete Anschlußbereiche mit jeweils einem Anschlußhaken und im wesentlichen radial nach innen ausgerichtete Kontaktzungen aufweisen, wobei der Leiterrohling aus einem längsstufenförmig profilierten metallischen Band hergestellt und im Bereich eines der Brückenteile ein Stoß vorhanden ist und die Brückenteile in Form von Wellen ausgeführt sind, die gegenüber den Leitersegmenten nach außen vorspringen und im wesentlichen dieselbe Wandstärke aufweisen wie die Leitersegmente. Ein solcher Leiterrohling läßt sich erkennbar mit Vorteil nicht nur bei dem vorstehend erläuterten Verfahren einsetzen. Vielmehr kann er mit übereinstimmenden Vorteilen auch bei abgewandelten Verfahren mit einer modifizierten Abfolge der Herstellungsschritte zum Einsatz kommen.It can be deduced from the above explanations of the method according to the invention that a particularly preferred ring-shaped conductor blank which can be used for a method for producing a planar commutator comprises a plurality of conductor segments uniformly arranged around an axis and two adjacent conductor segments each connecting bridge parts the conductor segments having substantially axially aligned terminal portions each having a connection hook and substantially radially inwardly directed contact tongues, wherein the conductor blank made of a Längsstufenförmig profiled metallic strip and in the region of the bridge parts a shock is present and the bridge parts are designed in the form of waves which protrude outwards relative to the conductor segments and have substantially the same wall thickness as the conductor segments. Such a conductor blank can be seen with advantage not only in the method described above. Rather, it can be used with matching advantages even in modified processes with a modified sequence of manufacturing steps.

Zur Verbesserung des elektrischen Kontakts zwischen den Leitersegmenten und den Kohlenstoffsegmenten ist gemäß einer bevorzugten Weiterbildung der vorliegenden Erfindung die Oberfläche des Leiterrohlings insgesamt, jedoch zumindest in den für einen Kontakt mit den - später aus der Kohlenstoffringscheibe hervorgehenden - Kohlenstoffsegmenten vorgesehenen Bereichen der Kontaktzungen versilbert oder verzinnt.In order to improve the electrical contact between the conductor segments and the carbon segments, the surface of the conductor blank as a whole is silvered or tinned, at least in the regions of the contact tongues provided for contact with the carbon segments, which later are made of the carbon ring disk.

Erkennbar ist es im Rahmen der vorliegenden Erfindung möglich, zur Herstellung einer Vielzahl übereinstimmender Leiterrohlinge ein längsstufenförmig vorprofiliertes metallisches Bandmaterial einzusetzen, dessen Breite im wesentlichen einem Vielfachen der Breite des zur Herstellung eines einzigen Leiterrohlings erforderlichen metallischen Bandes entspricht. Dabei können sogar jeweils zwei nebeneinander liegende Zuschnitte im Bereich der späteren Anschlußhaken ineinandergreifen, wodurch der Grad der Materialausnutzung nochmals gesteigert wird. Insoweit ist der Begriff "Rand" im Rahmen der vorliegenden Anmeldung so zu verstehen, daß er nur in dem Falle einen körperlichen Rand des streifenförmigen Bandes definiert, daß als Ausgangsmaterial ein metallisches Band-Flachmaterial mit einer solchen Breite zum Einsatz kommt, daß sich nicht mehrere nebeneinanderliegende Bandabschnitte ausstanzen lassen. Ist indessen letzteres der Fall, so gibt der Begriff "Rand" eine fiktive Begrenzung des betreffenden Ausschnitts aus dem Ausgangsmaterial, der zur Herstellung des jeweiligen Bandabschnitts dient, an.It is recognizable in the context of the present invention possible to use a longitudinally pre-profiled metallic strip material whose width substantially corresponds to a multiple of the width of the required for the production of a single conductor blank metallic strip for producing a plurality of matching conductor blanks. In this case, even two adjacent blanks in the region of the later connection hooks can intermesh, whereby the degree of material utilization is further increased. In that regard, the term "edge" in the context of the present application is to be understood that it defines only in the case of a physical edge of the strip-shaped tape, that as a starting material a metallic strip sheet is used with such a width that not several punch out adjacent sections of tape. If, on the other hand, the latter is the case, the term "edge" indicates a fictitious limitation of the relevant section from the starting material used to produce the respective strip section.

Im folgenden wird die vorliegende Erfindung anhand eines in der Zeichnung veranschaulichten bevorzugten Ausführungsbeispiels näher erläutert. Dabei zeigt

Fig. 1
in perspektivischer Angesicht einen in Anwendung der vorliegenden Erfindung vorgefertigten Leiterrohling, wie er zur Herstellung des in Fig. 4 gezeigten Plankommutators verwendet wird,
Fig. 2
einen Querschnitt durch das zur Herstellung des in Fig. 1 gezeigten Leiterrohlings verwendete längsstufenförmige Band,
Fig. 3
in Seitenansicht von der späteren radialen Innenseite hier den zur Herstellung des in Fig. 1 gezeigten Leiterrohlings verwendeten Bandabschnitt nach dem Ausstanzen der Randabschnitte und
Fig. 4
im Axialschnitt einen in Anwendung der vorliegenden Erfindung hergestellten Plankommutator.
In the following, the present invention will be explained in more detail with reference to a preferred embodiment illustrated in the drawing. It shows
Fig. 1
in perspective face a prefabricated in application of the present invention conductor blank, as he used for the production of in Fig. 4 used plan commutator is used,
Fig. 2
a cross section through the for the production of in Fig. 1 shown ladder blank used longitudinal step-shaped band,
Fig. 3
in side view of the later radial inner side here for the production of in Fig. 1 used conductor blank used band section after punching the edge portions and
Fig. 4
in axial section, a planar commutator produced in accordance with the present invention.

Der in Fig. 1 veranschaulichte ringförmig geschlossene Leiterrohling 1 umfaßt acht gleichmäßig um die Achse 2 herum angeordnete Leitersegmente 3 und acht Brückenteile 4, welche jeweils zwei benachbarte Leitersegmente 3 miteinander verbinden. Jedes Leitersegment weist einerseits einen im wesentlichen axial ausgerichteten Anschlußbereich 5 mit einem ebenfalls axial ausgerichteten Anschlußhaken 6 und andererseits eine im wesentlichen radial nach innen ausgerichtete Kontaktzunge 7 auf. Die Brückenteile 4 springen in Wellenform radial nach außen über die Anschlußbereiche 5 der Leitersegmente 3 vor. Ihre Wandstärke D1 entspricht der Wandstärke D2 der Anschlußbereiche 5 der Leitersegmente 3. Die Wellen erheben sich dabei so weit, daß der maximale Abstand ihrer Innenwand von der Achse 2 größer ist als der der Abstand der Außenwand der Anschlußbereiche 5 von der Achse 2.The in Fig. 1 illustrated annular closed conductor blank 1 comprises eight evenly around the axis 2 arranged around conductor segments 3 and eight bridge parts 4, which each connect two adjacent conductor segments 3 together. Each conductor segment has, on the one hand, a substantially axially aligned connection region 5 with a likewise axially aligned connection hook 6 and, on the other hand, a substantially radially inwardly aligned contact tongue 7. The bridge parts 4 project in waveform radially outward beyond the terminal portions 5 of the conductor segments 3. Their wall thickness D 1 corresponds to the wall thickness D 2 of the terminal portions 5 of the conductor segments 3. The waves rise so far that the maximum distance of its inner wall from the axis 2 is greater than the distance of the outer wall of the terminal portions 5 of the axis. 2

Hervorgegangen ist der Leiterrohling durch eine Reihe einfacher Umformschritte aus einem metallischen längsstufenförmigen Band 8 mit dem in Fig. 2 gezeigten Querschnitt. Das Band 8 weist auf seiner einen, ersten Seite 9, die die spätere radiale Innenfläche darstellt, eine erste Stufe 10 auf, die von dem dieser Stufe benachbarten ersten Rand 11 des Bandes 8 her eine Vergrößerung der Materialstärke bildet. Auf seiner der ersten Seite 9 gegenüberliegenden zweiten Seite 12, die die spätere radiale Außenfläche bildet, weist das Band 8 eine zweite Stufe 13 auf, die ihrerseits von dem ihr benachbarten zweiten Rand 14 des Bandes 8 her eine Vergrößerung der Materialstärke bildet. Die erste Stufe 10 und die zweite Stufe 13 halten einen Abstand A zueinander ein. Der zwischen der ersten Stufe 10 und der zweiten Stufe 13 liegende Bereich des Bandes 8 bildet dessen Hauptabschnitt H. Der zwischen dem ersten Rand 11 und der ersten Stufe 10 liegende Bereich des Bandes 8 bildet dessen ersten Randabschnitt 17. Und der zwischen dem zweiten Rand 14 und der zweiten Stufe 13 liegende Bereich des Bandes 8 bildet dessen zweiten Randabschnitt 18.The conductor blank has emerged from a series of simple forming steps from a metallic longitudinal strip 8 with the in Fig. 2 cross section shown. The band 8 has on its one, first side 9, which represents the later radial inner surface, a first step 10, which forms an increase in material thickness from the first edge 11 of the band 8 adjacent to this step. On its second side 12 opposite the first side 9, which forms the later radial outer surface, the band 8 has a second step 13, which in turn forms an enlargement of the material thickness from the adjacent second edge 14 of the band 8. The first stage 10 and the second stage 13 keep a distance A from one another. The region of the band 8 lying between the first step 10 and the second step 13 forms its main section H. The region of the band 8 lying between the first edge 11 and the first step 10 forms its first edge section 17 and that between the second edge 14 and the second stage 13 lying portion of the belt 8 forms the second edge portion 18th

Das Band 8 weist darüber hinaus im zweiten Randabschnitt 18 auf der ersten Seite 9 eine dritte Stufe 15 auf. An der dritten Stufe 15 nimmt die Materialstärke in Richtung auf den zweiten Rand 14 zu.The band 8 also has a third step 15 in the second edge section 18 on the first side 9. At the third stage 15, the material thickness increases in the direction of the second edge 14.

Zur Herstellung des Leiterrohlings 1 wird zunächst in einem ersten Arbeitsschritt von einem Vorrat des längsstufenförmig profilierten metallischen Bandes (Fig. 3) ein Abschnitt 16 ausgestanzt. Dabei werden zugleich die Anschlußhaken 6 in dem ersten Randabschnitt 17, die Kontaktzungen 7 in dem zweiten Randabschnitt 18 und teilweise dem Hauptabschnitt H und die Endbereiche mit zwei zueinander korrespondierenden Eingriffsabschnitten 19 und 20 eines schwalbenschwanzförmigen Schlosses 21 ausgestanzt. Sodann wird der Bandabschnitt 16 zur Bildung einer geschlossenen Ringstruktur rolliert, wobei das den Stoß sichernde Schloß 21 geschlossen wird. In einem weiteren Arbeitsschritt wird die Wellung in den ringförmig geschlossenen Bandabschnitt 16 eingebracht, indem - in einem entsprechenden Werkzeug - die Leitersegmente 3 durch entsprechende Radialstempel radial nach innen verschoben werden, während ein profiliertes Innenwerkzeug die Brückenteile 4 von radial innen abstützt. Anschließend werden in zwei Arbeitsschritten die Kontaktzungen 7 einwärts in Richtung auf die Achse 2 gebogen. Als nächstes werden dann die Kontaktbereiche durch eine axiale Scherung in zueinander korrespondierenden Ober- und Unterwerkzeugen profiliert, bevor abschließend durch einen Spaltschritt an den radialen Innenflächen der Anschlußbereiche 5 der Leitersegmente 3 Ankerteile 22 hergestellt werden.For the preparation of the conductor blank 1 is first in a first step of a supply of longitudinally profiled metal strip ( Fig. 3 ) punched out a section 16. At the same time, the connection hooks 6 in the first edge section 17, the contact tongues 7 in the second edge section 18 and partly the main section H and the end regions are punched out with two mutually corresponding engagement sections 19 and 20 of a dovetail-shaped lock 21. Then, the band portion 16 is rolled to form a closed ring structure, wherein the shock-locking lock 21 is closed. In a further step, the corrugation is introduced into the annularly closed band section 16 by-in a corresponding tool-the conductor segments 3 are displaced radially inwards by corresponding radial punches, while a profiled inner tool supports the bridge parts 4 from radially inward. Subsequently, the contact tongues 7 are bent inwards in the direction of the axis 2 in two steps. Next, the contact areas are then profiled by an axial shear in mutually corresponding upper and lower tools, before finally 3 armature parts 22 are produced by a gap step at the radial inner surfaces of the terminal portions 5 of the conductor segments.

Der so hergestellte Leiterrohling 1 wird in einem im wesentlichen bekannten Verfahren (vgl. DE 19956844 A1 ) zur Herstellung eines Plankommutators 23 mit Kohlenstoff-Bürstenlauffläche 24 weiterverarbeitet. Hierzu wird eine Kohlenstoffringscheibe mit dem Leiterrohling 1 unter Herstellung elektrisch leitender Verbindungen zwischen den Kontaktzungen 7 der Leitersegmente 3 und der Kohlenstoffringscheibe zu einem Verbundteil zusammengefügt. Das Verbundteil wird sodann in ein geöffnetes Spritzgießwerkzeug eingelegt. Das Spritzgießwerkzeug wird geschlossen. Dabei liegt ein erstes Teilwerkzeug an einer durch die erste Stufe 10, die Seitenflächen 25 der konischen Fußabschnitte 26 der Anschlußhaken 6 und die zugeordneten Stirnflächen 27 der Brückenteile 4 gebildeten ersten Dichtfläche an; und ein zweites Teilwerkzeug liegt an einer durch die zweite Stufe 13 und die zugeordneten Stirnflächen der Brückenteile 4 gebildeten zweiten Dichtfläche an. Alsdann wird der Trägerkörper 28 durch Einspritzen von plastifiziertem Preßstoff in das Spritzgießwerkzeug geformt. Nachdem der Preßstoff ausgehärtet ist, wird das Spritzgießwerkzeug geöffnet und der so entstandene Kommutatorrohling aus dem Spritzgießwerkzeug entnommen. Abschließend werden die Brükkenteile 4 durch Abdrehen entfernt, und die Kohlenstoffringscheibe wird durch Schnitte in einzelne Kohlenstoffsegmente 29 unterteilt. In Anbetracht dessen, daß das insoweit angewandte Verfahren aus dem Stand der Technik hinlänglich bekannt ist, kann auf eingehende Erläuterungen verzichtet werden. Hinzuweisen ist allerdings noch darauf, daß das Band 8, um das vorstehend beschriebene Abdrehen der Brückenteile 4 zu erleichtern, auf seiner zweiten Seite 12 im Bereich des Hauptabschnitts H eine vierte Stufe 30 aufweist, an der die Materialstärke in Richtung auf den ersten Rand 11 hin abnimmt.The conductor blank 1 produced in this way is produced in a substantially known process (cf. DE 19956844 A1 ) for producing a flat commutator 23 with carbon brush surface 24 further processed. For this purpose, a carbon ring disk is joined together with the conductor blank 1 to form a composite part to produce electrically conductive connections between the contact tongues 7 of the conductor segments 3 and the carbon ring disk. The composite part is then placed in an open injection mold. The injection mold is closed. In this case, a first part tool is located on a first sealing surface formed by the first step 10, the side faces 25 of the conical foot sections 26 of the connection hooks 6 and the associated end faces 27 of the bridge parts 4; and a second part tool abuts against a second sealing surface formed by the second step 13 and the associated end faces of the bridge parts 4. Then, the carrier body 28 is molded by injecting plasticized molding material into the injection mold. After the molding material has cured, the injection mold is opened and the resulting commutator blank from the Removed injection mold. Finally, the bridging parts 4 are removed by twisting, and the carbon ring disc is divided by cuts into individual carbon segments 29. In view of the fact that the method used so far is well known in the prior art, can be dispensed with detailed explanations. It should be pointed out, however, that in order to facilitate the turning of the bridge parts 4 described above, the strip 8 has on its second side 12 in the region of the main section H a fourth step 30 at which the material thickness in the direction of the first edge 11 points decreases.

Claims (17)

  1. A method for manufacturing a plane commutator (23) which comprises a carrier body (28) manufactured of pressed material, a plurality of conductor segments (3) evenly arranged around an axis (2) and anchored in the carrier body and comprises just as large a quantity of carbon segments (29) connected with said conductor segments in an electrically conductive manner which define the brush running surface (24), with the following steps:
    - providing of a ring-shaped closed conductor blank (1) with conductor segments (3) and bridge parts (4) each joining two neighbouring conductor segments with each other, wherein the conductor segments comprise substantially axially orientated connection regions (5) with a connection hook (6) each and contact tongues (7) which are substantially orientated radially;
    - providing of a carbon ring disc;
    - joining of the carbon ring disc and the conductor blank (1) into a composite part subject to manufacturing electrically conductive connections between the contact tongues (7) of the conductor segments (3) and the carbon ring disc;
    - inserting of the composite part in an opened injection mould;
    - closing of the injection mould;
    - moulding of the carrier body (28) through injecting plasticised pressed material into the injection mould;
    - removing of the commutator blank from the injection mould;
    - subdividing of the carbon ring disc into individual carbon segments (29) and removing or severing the bridge parts (4);
    characterized by the following prefabrication of the conductor blank;
    - providing of a metal longitudinal step shaped band (8) which is limited by a first edge (11) and a second edge (14) which is parallel with the former, wherein the band comprises a main section (H), which is limited through a first step (10) arranged adjacently to the first edge on the one, first side (9) of the band and a second step (13) arranged on the other, second side (12) of the band adjacent to the second edge, a second edge section (18) arranged between the first edge and the first step and a second edge section (18) arranged between the second edge and the second step and the material thickness of the band on the first and the second step each decreases from main section to the corresponding edge section and wherein furthermore the band on its first side (9) in the region of the second edge section (18) comprises a third step (15) on which the material thickness increases in direction of the second edge;
    - cutting off of a section (16) of the metal band (8) and punching-out of the two edge sections (17, 18) of the band for forming the connection hooks (6) in the first edge section (17) and the contact tongues (7) in the second edge section (18):
    - rolling the edge section (16) for forming a closed ring structure and working-in of a corrugation in the main section with flutes protruding in the region of the bridge parts (4) wherein the ring structure in the region of the flutes substantially has the same wall thickness (D1) as between the flutes;
    - bending of the contact tongues (7) inward in the direction of the axis (2);
    - profiling of the contact tongues (7) on both axial end faces through a shearing process in axial direction;
  2. The method according to Claim 1, characterized in that simultaneously a section (16) of the metal band (8) is cut off and the two edge sections (17, 18) of the band are punched out.
  3. The method according to Claim 1, characterized in that a section (16) of the metal band (8) is cut off first and subsequently the two edge sections (17, 18) are punched out.
  4. The method according to Claim 1, characterized in that a section (16) of the metal band (8) is cut off after the two edge sections (17, 18) of the band have been punched out.
  5. The method according to any one of the Claims 1 to 4, characterized in that the band section (16) is first rolled and subsequently the corrugation worked in.
  6. The method according to any one of the Claims 1 to 4, characterized in that the band section (16) is rolled after the corrugation has been worked in.
  7. The method according to any one of the Claims 1 to 4, characterized in that the band section (16) is rolled and the corrugation worked in simultaneously in a single operation for forming a closed ring structure.
  8. The method according to any one of the Claims 1 to 7, characterized in that during rolling of the band section (16) two engagement sections (19, 20) of a dovetail-shaped lock (21) which are provided on the ends of the main section (H) and which correspond to each other are joined with each other.
  9. The method according to any one of the Claims 1 to 8, characterized in that the bending of the contact tongues (7) inwards in direction of the axis (2) takes place in two steps.
  10. The method according to any one of the Claims 1 to 9, characterized in that through a gap step on the radial inner surfaces of the connection regions (5) of the conductor segments, armature parts (22) are manufactured.
  11. The method according to any one of the Claims 1 to 10, characterized in that the punching-out of the contact tongues (7) exclusively extends into the second edge section (18).
  12. The method according to any one of the Claims 1 to 11, characterized in that the punching-out of the connection hooks (6) extends into the main section (H).
  13. The method according to Claim 12, characterized in that the punching-out of the connection hooks (6) in the main section (H) is limited through conical edges.
  14. The method according to any one of the Claims 1 to 13, characterized in that the bridge parts (4) are completely removed by turning off in a single operation.
  15. Conductor blank (1) closed ring-shaped for use with a method according to Claim 1 for the manufacture of a plane commutator (23) comprising a plurality of conductor segments (3) evenly arranged about an axis (2) and two bridge parts (4) each joining two neighbouring conductor segments with each other, wherein the conductor segments comprise substantially axially orientated connection regions (5) each with a connection hook (6) and contact tongues (7) substantially orientated radially to the inside, characterized in that the conductor blank (1) is produced from a longitudinally step-shaped metal band (8), wherein in the region of one of the bridge parts (4) a joint is present and in that the bridge parts are embodied in form of waves, which relative to the conductor segments (3) project to the outside and substantially have the same wall thickness (D2) as the conductor segments.
  16. The conductor blank according to Claim 15,
    characterized in that in the region of the joint a dovetail-shaped lock (22) with two engagement sections (19, 20) arranged on the end side on the band (8) and which correspond with each other and engage with each other are provided.
  17. The conductor blank according to Claim 15 or Claim 16, characterized in that its surface at least in the regions of the contact tongues (7) intended for contact with the carbon segments (29) is silver-plated or tinned.
EP05770249A 2004-07-16 2005-06-30 Method for the production of a planar commutator and conductor blank for a planar commutator Not-in-force EP1769567B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL05770249T PL1769567T3 (en) 2004-07-16 2005-06-30 Method for the production of a planar commutator and conductor blank for a planar commutator

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102004034434A DE102004034434B4 (en) 2004-07-16 2004-07-16 Method for producing a flat commutator and conductor blank for a flat commutator
PCT/EP2005/007084 WO2006007952A1 (en) 2004-07-16 2005-06-30 Method for the production of a planar commutator and conductor blank for a planar commutator

Publications (2)

Publication Number Publication Date
EP1769567A1 EP1769567A1 (en) 2007-04-04
EP1769567B1 true EP1769567B1 (en) 2009-08-26

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP05770249A Not-in-force EP1769567B1 (en) 2004-07-16 2005-06-30 Method for the production of a planar commutator and conductor blank for a planar commutator

Country Status (14)

Country Link
US (1) US20070294877A1 (en)
EP (1) EP1769567B1 (en)
JP (1) JP4677449B2 (en)
KR (1) KR20070029251A (en)
CN (1) CN100544136C (en)
AT (1) ATE441228T1 (en)
BR (1) BRPI0513432A (en)
DE (2) DE102004034434B4 (en)
HK (1) HK1100591A1 (en)
MX (1) MX2007000596A (en)
PL (1) PL1769567T3 (en)
RU (1) RU2361339C2 (en)
UA (1) UA90859C2 (en)
WO (1) WO2006007952A1 (en)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101924315B (en) * 2009-06-16 2014-09-03 德昌电机(深圳)有限公司 Commutator and manufacturing method thereof
CN112775293A (en) * 2020-12-31 2021-05-11 巴博斯电子科技(苏州)有限公司 Stamping process for product with gap width-thickness ratio less than 1
CN112993712B (en) * 2021-02-23 2023-02-28 深圳市凯中精密技术股份有限公司 Manufacturing method of commutator copper shell, commutator copper shell and commutator

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0935331A1 (en) * 1997-08-21 1999-08-11 Aisan Kogyo Kabushiki Kaisha Commutateur of improved segment joinability

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Publication number Priority date Publication date Assignee Title
GB783210A (en) * 1955-05-16 1957-09-18 Lucas Industries Ltd Commutators for dynamo-electric machines or other electrical apparatus
DE2034502A1 (en) * 1970-07-11 1972-01-27 Bosch Gmbh Robert Commutator for electrical machines
JPS55157887A (en) * 1980-02-21 1980-12-08 Sugiyama Seisakusho Kk Method of manufacturing flat commutator
JPH0279751A (en) * 1988-09-16 1990-03-20 Sugiyama Seisakusho:Kk Flat type commutator and manufacture thereof
DE4028420A1 (en) * 1990-09-07 1992-03-12 Kautt & Bux Kg PLANKOMMUTATOR AND METHOD FOR THE PRODUCTION THEREOF
DE19525584A1 (en) * 1995-07-13 1997-01-16 Kautt & Bux Commutator Gmbh Method of manufacturing a flat commutator
US5925962A (en) * 1995-12-19 1999-07-20 Walbro Corporation Electric motor commutator
JPH10174375A (en) * 1996-12-09 1998-06-26 Denso Corp Commutator and its manufacture
US6114791A (en) * 1996-11-29 2000-09-05 Denso Corporation Commutator for motor using amorphous carbon and fuel pump unit using the same
DE19956844A1 (en) * 1999-11-26 2001-06-13 Kolektor D O O Flat commutator, process for its manufacture and blank and carbon disc for use in its manufacture
MXPA05006707A (en) * 2000-05-31 2005-09-08 Kolektor Group Doo Method of producing a flat commutator and a flat commutator produced according to said method.

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0935331A1 (en) * 1997-08-21 1999-08-11 Aisan Kogyo Kabushiki Kaisha Commutateur of improved segment joinability

Also Published As

Publication number Publication date
MX2007000596A (en) 2007-03-30
HK1100591A1 (en) 2007-09-21
KR20070029251A (en) 2007-03-13
BRPI0513432A (en) 2008-05-06
PL1769567T3 (en) 2010-01-29
EP1769567A1 (en) 2007-04-04
DE102004034434A1 (en) 2006-02-16
JP2008507246A (en) 2008-03-06
DE502005007993D1 (en) 2009-10-08
CN1985417A (en) 2007-06-20
RU2006146872A (en) 2008-08-27
ATE441228T1 (en) 2009-09-15
JP4677449B2 (en) 2011-04-27
US20070294877A1 (en) 2007-12-27
DE102004034434B4 (en) 2006-08-03
UA90859C2 (en) 2010-06-10
WO2006007952A1 (en) 2006-01-26
CN100544136C (en) 2009-09-23
RU2361339C2 (en) 2009-07-10

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