Abstract: A method and apparatus of fusing a pin to a wire to reliably form a good quality fusion joint includes placing the pin and insulated or uninsulated wire in a notch of a lower fusing electrode so that the pin is spaced a predetermined distance above the wire. The upper fusing electrode applies fusing current and heat symmetrically to the pin and notch side walls and the portion of the lower electrode beneath and in contact with the wire. Heat is transferred to soften the pin and burn or vaporize the insulation off the wire before the pin and wire touch. Since all parts are held symmetrically, parts can not skew or burn off unevenly. Electrode pressure builds to drive the soften, heated pin and wire together and to apply fusing current through the contacting pin and wire to form a good fusion joint. Another aspect of the invention includes forming the lower fusing electrode with a plurality of fusing notches to afford quick operator set-up and sequential, automatic fusing of the series of wire/pin assemblies.

Abstract: An electric motor according to the principles of the present invention includes a stator or stationary part of the motor and an armature. The armature includes a shaft having a rotation axis and a commutator subassembly fixed symmetrically to the shaft that includes an insulating body surrounding the shaft and a plurality of circumferentially spaced, carbon-based material segments surrounding the shaft. The carbon segments are held to the body and each segment has a brush contacting surface. An equal plurality of metallic commutator members have at least a part located and molded within the corresponding carbon segment for providing good mechanical and electrical connection between the carbon segment and metallic commutator member and to isolate the metallic part within the carbon segment from harmful external environments such as described above.