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Патент USA US3085961

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April 16, 1963
‘
e. P. BENTLEY ETAL
3,085,951
METHOD OF MAKING SLIP RING-LCOMMUTATOR DEVICES
Original Filed June 11, 1957
2 Sheets-Sheet 1
Fig.1
‘. INVENTORS
GEORGE P. BENTLEY
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-
_
GEORGE C. McNABB
EDWARD L. LEWIS
Fig-4
April 16, 1963
G. P. BENTLEY ETAL
3,085,951
METHOD OF MAKING SLIP RING-COMMUTATOR DEVICES
Original Filed June 11, 1957
2 Sheets-Sheet 2
Fig.5
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INVENTORS:
GEORGE P. BENTLEY
GEORGE C.MCNABB
EDWARD L. LEWIS -
BY
THEIR ATTORNEYS
3,?85,951
nite States
Patented Apr. 16., 1963
2
I
3,085,951
METHOD (PF MAKING SLIP RING-COMMUTATOR
DEVICES
George 1'’. Bentley, Franklin, George C. McNabb, Attic
boro, and Edward L. Lewis, Sharon, Mass., assignors
body portion 18 having ?rst and second annular ?anges
19 and 20 extending axially from opposite sides of the
body portion ?ush with the bottom surface thereof, and
third and fourth annular ?anges 22 and 23 extending
axially from opposite sides of the body portion ?ush with
to Instrument Development Laboratories, Inc., Attle
the top surface thereof. As seen in FIGURE 3 the third
bore, Mass, a corporation of New York
?ange 22 is longer than the fourth ?ange 23. Both the
third and fourth ?anges are further provided at their ends
with radially extending annular ?anges 24 and 25 thereby
Griginal application .Iune 11, 1957, Ser. No. 665,021, now
Patent No. 2,918,542, dated Dec. 22, 1959. Divided
and this appiication Oct. 5, 1959, Ser. No. 844,230
10 forming an annular channel in the outer surface of the
4 Ciairns. ((11. 204-146)
commutator ring. The commutator ring is thereafter
provided with equally spaced stepped radial slots 27 (FIG
The invention in this application, which is a division
URES 1 and 3) about its periphery from the channelled
of application Serial No. 665, 021, now APatent 2,918,542,
top surface down into the ?rst and second ?anges, the
relates to a method of making slip ring-commutator de
vices.
An object of the invention is to provide a method of
15 number of slots depending on the number of segments
desired for a particular application.
It is to be noted
making compact and rugged commutating devices partic
r
that the radial distances to the inner peripheries of both
the slip ring and commutator ring are equivalent.
ularly suited for use in high speed rotary switching
The outer retaining ring 14 (FIGURE 8) comprises an
devices.
Another object of the invention is in the provision of a 20 annular body portion 28 which has an axially extending
?ange 29 extending from one side ?ush with the ‘bottom
method of making integrated slip ring-commutator assem
thereof, and a relatively long axially extending ?ange 30
bles which permits of division of commutator segments
extending from the same side as ?ange 29 and ?ush with
with dividing head accuracy.
the top surface thereof. As seen in FIGURE 1, which
Another object of the invention is in the provision of
a method of making integrated slip ring-commutator as 25 illustrates as speci?c embodiment, the upper ?ange 30 is
provided with equally peripherally spaced axially extend
sembles having long electrical leakage paths between com
ing grooves 32, one‘of which has a substantially cutout
mutator segments.
portion 33, and with a plurality of similar relatively nar
Another object of the invention is in the provision of
row indexing or alignment reference grooves 34. Addi
a method of making slip ring commutator devices having
in line cylindrical commutating surfaces whereby phase 30 tionally the body portion 28 is provided with a plurality
of holes 35 about its circular face which in combination
errors due to brush width variations are eliminated.
with a potting compound provides strength ‘and rigidity
Other objects and many of the attendant advantages of
this invention will be readily appreciated as the same
becomes better understood by reference to the ‘following
detailed description when considered in connection with
the accompanying drawings in which like reference nu
to the assembled wafer.
In assembly the slip ring 12 is placed adjacent the
merals designate like parts throughout the ?gures thereof
commutator ring 13‘ with the flange 16 thereof overlap
ping the ?rst ?ange 19 of the commutator ring and main
tained spaced therefrom by .a separator ring 36 (FIGURE
and wherein:
FIGURE 1 is a plan view of an assembled slip ring
5) formed of an electrochemically active metal such as
aluminum. Electrochemically active keys 37 are also
commutator device;
FIGURE 2 is a top view of an assembled slip ring
cornmuntator device;
FIGURE 3 is a fragmentary perspective view of a
40 placed within the narrow portion of each of the stepped
radial slots 27 for reasons Which will hereinafter appear.
Insulated lead wires 38 are secured as by soldering to
predetermined ones of the segments 39 formed by said
slots in the commutator ring and a lead wire 46* to the
FIGURE 4 is a cross sectional view taken along lines 45 slip ring. The lead wires 38 and 40 are then caused
to lie flat in the annular channel 26 in the outer surface
4—4 of FIGURE 1;
of the commutator ring. The outer retainer ring 14 is
FIGURE 5 is a view in section through the commuta
then placed with its long ?ange 30 over both the slip
tor assembly prior to machining to separate the corn
ring and commutator ring and with its ?ange 29 between
mutator segments;
commutator ring before separation of the segments;
FIGURE 6 is a view in section through the commuta 50 the second and fourth ?anges 26‘ and 23 of the com
mutator ring; the lead wires being brought out through
tor following machining to separate the commutator seg
the cutaway groove 33 (FIGURES 2 and 5). The rings
ments and expose the inserts to enable them to be re
disposed with respect to each other as described above are
moved by electrolytic etching;
held in a suitable jig and a plotting compound 42 of
FIGURE 7 is a view in section taken through one side
of the slip ring; and
FIGURE 8 is a view in section taken through one side
of the outer retaining ring of the commutator slip ring
device.
Referring now to the drawings wherein like reference
characters designate like or corresponding parts through
out the several views, and particularly to FIGURES 3, 4,
7 and 8, the slip ring-commutator construction comprises
a slip ring 12, a commutator ring 13, and an outer retain
55 insulating material such as an epoxy resin whose co
e?icient of thermal expansion matches that of the metal
parts is poured into and ?lls all the slots in and spaces
around and between the intermeshing ?anges of the rings
‘and the wide portion of the stepped slots 27 between
segments whereby the assembly becomes an integrated
annular wafer of great strength and rigidity. The result
ing wafer is disclosed in FIGURE 5.
Thereafter the wafer is placed on a lathe and the inner
surfaces of the slip ring and commutator ring (shown
ing ring 14. The slip ring comprises an annular body
portion 15 having annular ?anges 16 and 17 extending 65 dotted in FIGURE 4) are turned down until the bottom
of the radial slots 27 (FIGURE 3), which extend down
axially from diametrically opposite sides of the body
into the lower ?anged body portion of the commutator
portion ?ush with the top and bottom surfaces of the
ring are reached (line 43) thereby dividing the commuta
body portion. Flange 16 is relatively thinner than ?ange
tor ring into individual segments insulated from one an
17 and is radially slotted about its periphery.
70 other and exposing inner edges of the keys 37 as shown
The commutator ring 13 preferably formed of rhodium
in FIGURE 6. Thereafter the remainder of aluminum
comprises as most clearly seen in ‘FIGURE 3 an annular
3,085,951
3
insert 35 separating the slip ring and commutator ring and
2. The method of making slip ring-commutator wafers
the keys 37 within the narrow portion of the stepped
radial slots 27 are electrochemically etched away to pro
having a slip ring and a commutator ring of equivalent
internal diameter, said rings having irregular cross sec
vide undercut segments as shown in FIGURE 4. As is
tions, said method comprising the steps of forming sub
stantially radially extending slots in said commutator ring
extending inwardly from its outer periphery, said slots
having inner ends spaced outwardly from the inner
periphery of said commutator ring to form a plurality
of segments joined together by an inner peripheral annular
web, inserting electrochemically active metal keys in said
apparent, the contact surfaces of the segments are cylin
drical sections thereby permitting accurate timing.
The above method permits division of the commutator
segments 39 from one another with dividing head accuracy
as they are an integral part of the retaining ring 14 during
embedment. The above method which is termed “double 10
inner ends of said slots, placing said rings adjacent one
slotting" provides a commutator having long electrical
leakage paths between segments with concomitant high
another with their cross sections spaced from and over
intersegment resistances. The leads 38 which as here
tofore stated are brought out through one grooved sec
tion of the retaining ring ?ange as shown in FIGURE 2
are adapted when the ring or rings are assembled within
a cylindrical casing to lie within the groove 32 thereof as
lapping each other, ?lling said spaces between said rings
seen in the assembled view of FIGURES l and 2.
thereafter etching away said keys to provide undercut
segments.
3. The method of making commutators comprising
the steps of cutting stepped radial slots in the outer
periphery of ‘a cylindrical ring, said slots having inner
ends spaced from the inner periphery of said ring, insert
ing electrochemically active metal keys in said inner ends
It should be understood, that the foregoing disclosure
relates to only a preferred embodiment of the invention
and that it is intended to cover all changes and modi?ca
tions of the example of the invention herein chosen for
the purposes of the disclosure, which do not constitute
departures from the spirit and scope of the invention.
The invention claimed is:
1. The method of making annulated wafer like com
mutators having ?rst and second rings of equivalent in
and segments with a potting compound to secure said
rings and segments together and electrically insulate them
from one another, cutting away said web to separate said
segments from each other and expose said keys and
of said slots, ?lling the remainder of said slots with a
bonding insulating material, boring out the internal sur
face of said slotted ring to expose said inner ends of said
slots and said keys therein to separate said ring into seg
ternal diameters, said ?rst ring having an annular body
ments, and thereafter electrochemically etching away said
portion, ?rst and second ?anges extending axially from
diametrically opposite sides of and ?ush with the radially 30 keys to provide undercut segments.
‘4. A method of making commutators comprising form
outer and radially inner surfaces thereof, said second ring
ing stepped slots of progressively narrower width extend
having a body portion, ?rst and second ?anges extending
ing from one side of a metallic commutator ring toward
axially from opposite sides of and ?ush with the radially
an opposite side thereof, said slots having closed ends
inner surface thereof, third and fourth ?anges extending
spaced substantially equal distances from said opposite
axially from opposite sides of and flush with the radially
side of said ring, inserting keys in said slots adjacent to
outer surface thereof and ?fth and sixth ?anges extending
the closed ends thereof, the remaining portions of said
radially from and ?ush with the ends of said third and
slots being open, ?lling the open portions of said slots
fourth ?anges, said method comprising the steps of,
with, and at least partially embedding said ring in, a
forming slots in said second ring, said slots extending
inwardly from the radially outer surface of said second 40 bonding insulating material, cutting away said ring from
said opposite side to said closed ends of said slots to divide
ring and having inner ends spaced from the radially inner
said ring into a plurality of separate segments and expose
surface of said second ring, inserting electrochemically
active metal keys in said slots adjacent to said inner ends,
placing said ?rst and second rings adjacent one another
with said second ?ange of the ?rst ring overlying and
spaced from said ?rst ?ange of said second ring, ?lling
the spaces between said intermeshing rings with an in
sulating potting material, radially boring said radially
inner surface of said second ring through to the slots
thereby dividing said second ring into a plurality of radial ‘
segments and exposing said keys therebetween, and there
after electrochemically etching away said keys to provide
separate, undercut segments.
a portion of each key therebweteen, and thereafter re
moving said keys from between said segments.
References Cited in the ?le of this patent
UNITED STATES PATENTS
1,195,861
1,624,597
1,845,115
2,156,156
2,936,519
Smith _______________ __ Aug.
Heathcote ____________ .._ Apr.
Apple ______________ __ Feb.
Mahlck ______________ __ Apr.
Blackman ____________ __ May
22,
12,
16,
25,
17,
1916
1927
1932
1939
1960
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