EP0629028A2 - Geräte und Verfahren zum Markieren und Erkennen von Kollektorhaken in elektrischen Motoren - Google Patents

Geräte und Verfahren zum Markieren und Erkennen von Kollektorhaken in elektrischen Motoren Download PDF

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Publication number
EP0629028A2
EP0629028A2 EP94108608A EP94108608A EP0629028A2 EP 0629028 A2 EP0629028 A2 EP 0629028A2 EP 94108608 A EP94108608 A EP 94108608A EP 94108608 A EP94108608 A EP 94108608A EP 0629028 A2 EP0629028 A2 EP 0629028A2
Authority
EP
European Patent Office
Prior art keywords
fusing
hook
workpiece
electrode
displacement
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP94108608A
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English (en)
French (fr)
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EP0629028A3 (de
Inventor
Luciani Sabatino
Massimo Lombardi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Axis SpA
Original Assignee
Axis SpA
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Filing date
Publication date
Application filed by Axis SpA filed Critical Axis SpA
Publication of EP0629028A2 publication Critical patent/EP0629028A2/de
Publication of EP0629028A3 publication Critical patent/EP0629028A3/de
Withdrawn legal-status Critical Current

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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
    • H01R39/32—Connections of conductor to commutator segment

Definitions

  • the present invention relates to armature winding machines, and, more particularly, to machines for winding the armature wires of an electric-motor to a hook member ("tang") of a commutator bar and deforming selected hook members for later identification during processing.
  • the conditions required for fusing commutator hooks vary depending upon the number of armature lead wires that are passed around a given hook.
  • the fusing conditions must be tailored to the hook's winding configuration if a satisfactory fusion joint is to be formed. For example, a hook with a single wire passed around it will require a different electrode displacement, electrode force, and electric current application than a hook with two wires passed around it.
  • the hook wrapped with two wires may require additional electrode force to produce a cohesion joint of satisfactory quality.
  • Winding machines typically attach two armature lead wires to selected hooks during the termination stages of armature winding. At the instant a hook is wrapped with two wires, the armature has a precise, known angular position. Thus, it would be possible to transfer a wound armature to a fusing machine while in a known angular position. The hooks wrapped with two wires could be recognized by their angular position and appropriately processed. However, such a solution requires costly changes to the transfer solutions between the winding and fusing machines.
  • a winding machine which deforms preselected commutator hooks, yet does not deform other hooks.
  • the machine deforms the hooks while the hooks are in a known angular position.
  • Apparatus is provided, for processing the hooks after winding, which includes means for measuring: (1) the hook deformation; (2) the force exerted on a sensing member, or (3) a signal applied across the electrode which varies when the fusing electrode makes contact with the tang.
  • a machine for processing the hook such as a fusing machine, which includes a force transducer for measuring electrode pressure, and an encoder for accurately determining the electrode displacement.
  • the electrode force and displacement measurements will vary, depending upon whether or not the electrode is operating on a hook that was deformed by the winding machine.
  • a microprocessor-based control system receives force and displacement data from the load cell and encoder, respectively, and acts on a motor to modify those quantities.
  • the microprocessor recognizes hooks that were previously deformed by the winding machine, and causes the fusing machine to execute a predetermined operation. The operation performed on a deformed hook may be different than the operation performed on a non-deformed hook.
  • a machine for processing the hook such as a fusing machine
  • a machine for processing the hook such as a fusing machine
  • a microprocessor-based control system receives signal and displacement data from the load cell and encoder, respectively, and acts on a motor to modify those quantities.
  • the microprocessor recognizes hooks that were previously deformed by the winding machine, and causes the fusing machine to execute a predetermined operation. The operation performed on a deformed hook may be different than the operation performed on a non-deformed hook.
  • the microprocessor stores a distinct, predetermined electrode displacement or force function for fusing each hook variation that the apparatus can process. Electrode position or force may be continuously measured and adjusted according to the appropriate function.
  • the apparatus applies current to the electrode when the electrode has a predetermined displacement or force, and may vary the current application according to whether or not the hook under operation was deformed (marked) by the winding machine.
  • FIGS. 1-8 illustrate the process for winding a lead wire 10 of an armature to a commutator bar 12.
  • Wire 10 is wrapped around a hook 14 on commutator bar 12.
  • a two-flyer winding machine 16 removes wire 10 from a coil and passes it around hook 14.
  • An unwound armature 18 rests on winding machine 16 in winding receiving position.
  • Wire 10 passes around a roller 20 and then around a flyer 22.
  • Wire 10 stretches from flyer 22 to a gripper 24.
  • Gripper 24 reciprocates during winding to draw wire 10 from a supply roll and over roller 20 and flyer 22.
  • the gripper's reciprocating action attaches the wire lead to hook 14 (FIG. 2).
  • Initial and final leads are attached to the appropriate hooks and then cut by the operation of flyer 22, gripper 24, a cutter, and other equipment.
  • start lead 26 (FIG. 3) is attached to the armature around a first hook by rotation of flyer 22. Wire 10 is then cut (see FIGS. 4 and 4a) between hook 14 and gripper 24 (near the hook) to free gripper 24 and leave start lead 26 wrapped around the hook.
  • Flyer 22 and other equipment then operate to wind wire coils in the appropriate armature slots, and to loop the wire around the respective hooks.
  • a single wire is passed around each hook (see FIG. 5) when the coils are being wound. The continuity of the wire is not interrupted.
  • flyer 22 When flyer 22 has completed winding all of the coils that must be wound, a stretch of wire extends from the flyer to the last wound coil. Flyer 22 and other equipment then operate to loop the finish lead 28 around the last hook (see FIG. 6). Gripper 24 grips the stretch of wire leading from the hook to the flyer, and the wire is severed at a point near the hook. A new armature may then be wound.
  • FIG. 7a shows the start and finish leads of the two flyers wrapped behind the same hook.
  • the start and finish leads may be on a hook which is also wrapped with an uninterrupted lead (FIG. 7b).
  • the armature is rotated with the same equipment used to hold and rotate the armature during winding.
  • the hooks wrapped with more than one wire are positioned under a deforming member 30.
  • Deforming member 30 is displaced a predetermined distance along the deforming axis 31 to deform the hooks wrapped with two wires.
  • Member 30 is driven by numerically-controlled axial actuators for high precision operations or when more than one deformed position is required. When less precision is required, conventional, less complex actuators can be used to drive deforming member 30.
  • a plurality of deforming members may be used to increase operating speed.
  • the deformed hooks 32 are bent towards the commutator bar 33.
  • Deforming member 30 typically may be part of the winding apparatus. Hook 32 may be deformed while still in its winding position with a known angular position. Alternatively, the deforming step may be performed by a machine (FIG. 9) that unloads the armature from winding machine 16 and places it on a transfer mechanism. The armature is removed from the winding machine and positioned beneath deforming member 30. An activator 34 controls a collet 35, which releasably holds the shaft of the armature in a known angular position. A shuttle 36 is moved by member 37 along guides 38 to withdraw the armature from winding machine 16, positioning the armature adjacent deforming member 30. After member 30 marks the appropriate hook, the armature may be transferred to other equipment for further processing.
  • deformed hook 32 has a different position, relative to commutator bar 33, than the upper surface of non-deformed hooks 14.
  • Apparatus that is sensitive to force exerted on a translating member, or which can detect the displacement of a translating member along an axis of translation, is used to distinguish deformed hooks 32 (wrapped with several wires) from non-deformed hooks 14 (wrapped with a single wire). In this manner, subsequent processing equipment, such as a fusing machine, can automatically identify hooks wrapped with more than one wire.
  • Distinguishing between the commutator hooks wrapped with more than one wire and hooks wrapped with a single wire enables the fusing machine to perform a different fusing operation on each type of hook.
  • Deforming hooks during the winding operation offers the additional advantage of exerting additional pressure on the wrapped wires. This aids in holding the wires under the hook during subsequent transfer and handling of the armature.
  • Fusing machines capable of recognizing hooks deformed during the winding operation typically include one or more sensing elements.
  • the sensing elements measure force exerted on a hook as a function of time or as a function of fusing electrode displacement. Alternatively, the sensing elements detect electrode displacement as a function of time or electrode force.
  • Fusing apparatus suitable for this purpose is described in commonly owned, co-pending U.S. patent Application Serial No. 07/412,279, which is hereby incorporated by reference herein.
  • the fusing operation may be tailored to the condition of the particular hook being fused. This permits a better fusion joint to be produced.
  • the heat i.e., electric current
  • force applied to the hooks, and the displacement performance of the electrode are tailored to obtain the ideal fusing condition, which results in the correct electrical resistance and sufficient mechanical resistance of the connection.
  • a fusing electrode typically must generate more heat to fuse a hook wrapped with two wires in order to remove the greater quantity of wire insulation. The extra heat must be combined with the appropriate force and displacement performance of the electrode.
  • FIG. 10 shows a fusing machine in which the rotational motion of a motor 40 is converted into translational motion of fusing electrode 42 along axis 31.
  • a rotation of motor output drive shaft 44 will cause a ball screw 46 to rotate.
  • the engagement of ball screw 46 with sleeve 48 causes hollow member 50, hollow member 52, and electrode 42 to translate along electrode axis 31.
  • a roller 54 maintains the alignment of hollow members 50 and 52 along axis 31.
  • a force transducer such as load cell 56
  • a space 58 allows hollow member 52 to translate along hollow member 50, and allows load cell 56 to deform correspondingly.
  • a mass electrode 60 contacts the commutator during fusing to provide a current sink for electricity flowing from electrode 42.
  • the fusing machine can monitor and adjust the electrode displacement and force.
  • the displacement is derived, using encoder 62, from the number of turns of motor drive shaft 44.
  • Load cell 56 measures the force resistance against the electrode.
  • Microprocessor circuit 66 acts in response to data received from either the encoder or the load cell.
  • Microprocessor circuit 66 causes the motor to precisely lower (or raise) electrode 42.
  • the microprocessor changes the field conditions of motor 40 to control the motor's torque.
  • the apparatus can be used to implement the feedback loops shown in FIGS. 12 and 13, to distinguish deformed hooks from non-deformed hooks, and to perform a different processing operation on each type of hook.
  • a feedback measurement loop provides a means for displacing a fusing electrode of a fusing machine a predetermined distance, corresponding to a position slightly below the upper surface of a non-deformed hook (step A).
  • the feedback loop measures the force on the electrode (step B). If the electrode force is within a predetermined range, the hook is recognized as a hook wrapped with a single wire.
  • the hook is then fused according to a predetermined electrical current application function and electrode force or displacement function (step C), e.g., as shown in copending U.S. patent Application Serial No. 07/412,279.
  • the electrode is displaced to a second predetermined position, which corresponds to a position slightly below the upper surface of a hook deformed in accordance with this invention (step D).
  • the electrode force is again measured (step E). If the electrode force is within a predetermined range, the hook is recognized as a hook wrapped with two wires. The hook and wires are then fused according to a predetermined electrical current application function and electrode force or displacement function (step F), e.g., see U.S. patent Application Serial No. 07/412,279. If the force is not in the predetermined range, the armature is rejected (step G).
  • a different feedback loop provides an alternative means for recognizing a deformed hook.
  • a fusing electrode is translated along the electrode axis until it encounters a force resistance that is within a predetermined range, which corresponds to the electrode contacting the hook (step A).
  • the feedback loop measures the electrode displacement and determines whether the displacement corresponds to the expected height of the upper surface of a non-deformed hook, a deformed hook, or an abnormal hook (step B). If the electrode displacement corresponds to the height of a non-deformed hook, the hook is recognized as being wrapped with a single wire.
  • the hook and wire are then fused according to a predetermined electrical current (heat) application function and electrode force or displacement function appropriate for fusing a hook wrapped with a single wire (step C).
  • the hook may be fused according to the method disclosed in U.S. patent Application Serial No. 07/412,279. If the electrode displacement corresponds to the height of a deformed hook, the hook is recognized as a hook wrapped with two wires.
  • the hook is then fused using appropriate force, displacement, and electrical current (heat) application functions (step D), e.g., according to U.S. patent Application Serial No. 07/412,279. If the displacement does not correspond to the height of either a deformed or non-deformed hook, the armature is rejected (step E).
  • a hook wrapped with more than one wire may be recognized, and thereby distinguished from a hook wrapped with a single wire, by its response to electrode force and displacement when being deformed (see FIG. 14).
  • the force transducer will detect a greater force than normally detected for single wire hooks (step B).
  • the measured force and displacement responses of a given hook are compared to predetermined functions (e.g., force functions) stored in the microprocessor circuitry, and the hook is identified as being wrapped with one or more wires, or as abnormal (steps C-E).
  • Control circuit 70 includes microprocessor 72, which comprises at least one conventional analog-to-digital card 74 and at least one conventional input-output card 76, switch 78 and predetermined voltage supply 80, which in the present case may be set at a convenient voltage, such as 24 volts.
  • Switch 78 which is controlled by microprocessor 72 via activate line 82, has an input connected to voltage supply 80 and an output connected to electrode 42 and to microprocessor input-output card 76.
  • mass electrode 60 is connected to a return terminal (not shown) of voltage supply 80, and is also connected to input-output card 76, although this connection may be made via any other means in contact with hook 14.
  • displacement of electrode 42 is measured by encoder 62, which, in this alternate embodiment, has an output connected to analog-to-digital card 74.
  • displacement of electrode 42 may be measured by a position transducer (not shown).
  • voltage supply 80 should be implemented such that it can withstand short circuits without failure.
  • a resistive element (not shown) may be connected between supply 80 and switch 78, or wherever is most convenient, to provide a load when short circuits occur between the terminals of supply 80 to protect supply 80. Any other conventional means of protecting supply 80 may also be used (e.g, supply 80 may itself be constructed to withstand short circuits so that external protection is not required).
  • Circuit 70 essentially operates by applying a signal voltage from supply 80 through switch 78 across electrodes 42 and 60 (or other means in contact with hook 14). During electrode movement, before a fusing current is applied, displacement of electrode 42 is measured. When electrode 42 comes into contact with hook 14, the potential difference across electrodes 42 and 60 changes because a current path is established through hook 14. This variation in potential can be recognized by microprocessor 72 because it is programmed to identify variations that fall within the interrupt limits of the microprocessor. When the variation occurs, microprocessor 72 records the current displacement of electrode 42 in order to determine whether the hook is deformed or not. Two typical alternative feedback loops to implement this apparatus for distinguishing between deformed and non-deformed hooks are shown in FIGS. 16 and 17.
  • a different feedback loop provides an alternative means for recognizing a deformed hook.
  • Switch 78 is closed, which causes a signal voltage to be applied across electrodes 42 and 60 (step A).
  • Fusing electrode 42 is then translated along electrode axis 31 until a variation in the signal potential across the electrodes is sensed, which corresponds to electrode 42 contacting the hook (step B).
  • the feedback loop measures the electrode displacement and determines whether the displacement corresponds to the expected height of the upper surface of a non-deformed hook, a deformed hook, or an abnormal hook (step C). If the electrode displacement corresponds to the height of a non-deformed hook, the hook is recognized as being wrapped with a single wire.
  • the hook and wire are then fused according to a predetermined electrical current (heat) application function and electrode force or displacement function appropriate for fusing a hook wrapped with a single wire (step D).
  • the hook may be fused according to the method disclosed in U.S. patent Application Serial No. 07/412,279. If the electrode displacement corresponds to the height of a deformed hook, the hook is recognized as a hook wrapped with two wires.
  • the hook is then fused using appropriate force, displacement, and electrical current (heat) application functions (step E), e.g., according to U.S. patent Application Serial No. 07/412,279. If the displacement does not correspond to the height of either a deformed or non-deformed hook, the armature is rejected (step F).
  • FIG. 17 another feedback loop provides an alternative means for recognizing a deformed hook.
  • Switch 78 is closed, which causes a signal voltage to be applied across electrodes 42 and 60 (step A).
  • Fusing electrode 42 is then translated along electrode axis 31 until a predetermined displacement is reached, within given tolerances (step B).
  • the feedback loop determines whether a variation in potential across the electrodes has occurred (step C). If a variation in potential has occurred, the hook is a non-deformed hook and is recognized as being wrapped with a single wire.
  • the hook and wire are then fused according to a predetermined electrical current (heat) application function and electrode force or displacement function appropriate for fusing a hook wrapped with a single wire (step D).
  • the hook may be fused according to the method disclosed in U.S. patent Application Serial No. 07/412,279. If a variation in potential has not occurred, the hook may be assumed to be a deformed hook and the hook is recognized as a hook wrapped with two wires. The hook is then fused using appropriate force, displacement, and electrical current (heat) application functions (step E), e.g., according to U.S. patent Application Serial No. 07/412,279. Another test may be made, but is not required, where the potential is checked at a second displacement to ensure that the hook has been deformed properly. If no variation in potential occurs by the time the second displacement is reached, the armature should be rejected (step not shown).

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
EP94108608A 1993-06-09 1994-06-06 Geräte und Verfahren zum Markieren und Erkennen von Kollektorhaken in elektrischen Motoren. Withdrawn EP0629028A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US7430993A 1993-06-09 1993-06-09
US74309 1993-06-09

Publications (2)

Publication Number Publication Date
EP0629028A2 true EP0629028A2 (de) 1994-12-14
EP0629028A3 EP0629028A3 (de) 1996-07-17

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Application Number Title Priority Date Filing Date
EP94108608A Withdrawn EP0629028A3 (de) 1993-06-09 1994-06-06 Geräte und Verfahren zum Markieren und Erkennen von Kollektorhaken in elektrischen Motoren.

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EP (1) EP0629028A3 (de)
CA (1) CA2124042A1 (de)

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4792714A (en) * 1988-02-01 1988-12-20 General Motors Corporation Commutator with non-uniform bars and equally spaced hooks
US5122975A (en) * 1989-11-30 1992-06-16 Axis Usa, Inc. Methods and apparatus for marking and identifying hooks of electric motors

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CA2124042A1 (en) 1994-12-10
EP0629028A3 (de) 1996-07-17

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