Commutator having a plurality of commutator segments and method for making the same

摘要

A commutator has a plurality of commutator segments fixed to an insulating support member. The commutator segments are formed by cold or hot forming a copper billet cut from a length of copper wire. Each billet has a volume approximately equal to the volume of one commutator segment. Each commutator segment has a main body and an anchor integrally formed with the main body. The commutator segments are spaced about a circle and then an insulating support member is molded to the commutator segments to fix the commutator segments to the support member.

主权项

1. A method of making a commutator having a plurality of commutator segments fixed to an insulating support member, the method comprising the steps of:
providing a plurality of copper billets; providing a cold heading treatment to each copper billet to form a cold headed copper billet, each cold headed copper billet having a first portion at one axial end and a second portion at the other axial end, the first portion has a diameter smaller than the second portion; pressing each cold headed copper billet into a commutator segment having a main body and at least one anchor integrally formed with the main body; soldering the commutator segments to a conductive ring so that the commutator segments are spaced about a circle; molding an insulating support member to the arranged commutator segments to fix the commutator segments to the support member; and dividing the conductive ring into a plurality of graphite sectors, each graphite sector being fixed with one corresponding commutator segment.