Abstract: A commutator, having extremely exact geometrical dimensions and a long-time stability and being easy to produce, includes a pre-shaped, substantially cylindrical support body with a rotational axis. Electrically conductive commutator segments are fixed on the support body by fasteners arranged substantially between the commutator and the segments. The support body and the segments are provided with interacting structures to position and adjust the segments relative to the support body.

Abstract: Commutators for electro-dynamic machines such as electric motors comprise a cylindrical shell of insulated commutators bars, each of which has an outer layer with tangs extending from the outer layer and an inner layer with anchoring tabs extending therefrom. The commutating bars are typically produced from two strips of copper or other conductive metal. The inner layer may be formed of a thinner but stronger material, even of a non-conductive material, but is normally preferable to use two strips of copper to facilitate fusion of the materials together. The first strip, which is typically somewhat thicker than the second, is formed by punching so that partially formed tangs extend laterally from the side of the strip. The second strip is formed in a similar process to provide anchoring tabs extending from the sides of the second strip. These commutators can be produced economically and efficiently and can be adapted to a wide variety of applications and requirements.

Abstract: In the case of a plug-in commutator with a hub body (1) consisting of an electrical isolation material and having evenly distributed and positioned grooves of like design over its circumference, in which each of the segments (5)--of like design--which form the commutator path, is inserted by forming a form-fit connection in radial direction, the segments (5) are safeguarded from a shift in relation to the hub body (1) by a clamping force that is based on an overdimension (x, z) of the segments (5) and/or of material parts of the hub body (1) that facilitate the positioning of the segments (5). Only in the area of the two end sections (18, 21) of the segments (5) and/or the grooves is the overdimension (x, z), which determines the clamping force exerted on the segments (5), provided.

Abstract: A method of making a carbon commutator is provided. The method includes the steps of providing a planar substrate having a series of current-carrying regions; providing a carbon base having a brush-contacting surface and a second opposite surface; substantially covering the second surface of the carbon base with a conductive plating to form an unslotted commutator body; applying a conductive bonding layer to the conductive plating; bonding the unslotted commutator body to the substrate; and cutting corresponding slots in the commutator body to form a series of commutator segments.

Abstract: A fuel pump and the method for making the fuel pump designed for operation in an environment of a hydrocarbon fuel having a significant portion of oxygen-containing moieties are disclosed. The pump consists of a body, a shaft, a commutator, and brushes in contact with the commutator; the method of making the commutator comprises the steps of affixing a formed carbon article to a suitable substrate, machining the article to a commutator, and cutting slots into the commutator. In one embodiment, the method includes forming the carbon article directly on the substrate prior to the machining steps.