Abstract: A method for insulating wires is disclosed. A portion of the plurality of wires and an insulating material are placed in a tube having an open end. Pressure is applied to the tube. During the application of pressure, the tube, the plurality of wires, and the insulating material are heated to a temperature above a melting point of the insulating material. As a result, the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.

Abstract: A method for insulating wires is disclosed. A portion of the plurality of wires and an insulating material are placed in a tube having an open end. Pressure is applied to the tube. During the application of pressure, the tube, the plurality of wires, and the insulating material are heated to a temperature above a melting point of the insulating material. As a result, the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.

Abstract: A method for insulating wires is disclosed. A portion of the plurality of wires and an insulating material are placed in a tube having an open end. Pressure is applied to the tube. During the application of pressure, the tube, the plurality of wires, and the insulating material are heated to a temperature above a melting point of the insulating material. As a result, the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.

Abstract: A method for insulating wires is disclosed. A portion of the plurality of wires and an insulating material are placed in a tube having an open end. Pressure is applied to the tube. During the application of pressure, the tube, the plurality of wires, and the insulating material are heated to a temperature above a melting point of the insulating material. As a result, the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.

Abstract: A method and apparatus of making an electrical bobbin including applying to the wire/terminal assembly fusing pressure and heat. Sensing the temperature of an electrode zone near one of its fusing surfaces, and controlling the application and cessation of fusing power in response to the zone temperature values. Power application can cycle on and off for a set time period, number of set cycles, or stopped in response to another event such as sensed electrode displacement reaching a set value. Various other control parameters are or can be employed. The electrodes are preferably high resistant material and no significant current flows between upper and lower electrodes.

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 symmetically, parts can not skew or burn off un evenly. 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.

Abstract: A method, machine and termination for connecting two or more insulated wire ends comprises placing them in a metal tube held between fusing electrodes. The electrodes are shaped to deform the tube and wires therein with the application of fusing pressure. During fusing, pressure builds first to press the assembly together, then heat and current are applied as the tube and internal wires are compressed. Fusing current first flows from a longitudinal region of the tube equally in both direction through the tube metal to soften the tube and distribute the fusing heat broadly. As the wire insulation is burned off or flows away, current also passes through the bare wire ends to aid the fusing process. For tinned copper tubes, some of the inside tin layer flows to wet copper surfaces and dissolve copper impurities. Some tin flows to seal small spaces between the fused wires. Some of the tin on the outside surface and inside surface of the tube may vaporize.

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.

Abstract: A method and product of making a motor armature that includes a carbon disk or carbon barrel commutator subassembly with the carbon layer soldered to the metal commutators. The novel method includes, while fusing the armature wire segment to each metal commutator, applying cooling liquid to the commutator segment being fused and/or the fusing electrode in order to remove or reduce heat transfer to the solder layer. This technique yields many benefits to the process and product, including (1) overheating, flow, and beading of the solder is avoided, (2) temperature rise of the electrode and fused joint can be better controlled, (3) application of power and power consumption can be more uniformly achieved, and (4) better repeatability, yield, and quality of product can be achieved.

Abstract: A method, machine and termination for connecting two or more insulated wire ends includes placing them in a metal tube held between fusing electrodes. The electrodes are shaped to deform the tube and wires therein with the application of fusing pressure. During fusing, pressure builds first to press the assembly together, then heat and current are applied as the tube and internal wires are compressed. Fusing current first flows from a longitudinal region of the tube equally in both direction through the tube metal to soften the tube and distribute the fusing heat broadly. As the wire insulation is burned off or flows away, current also passes through the bare wire ends to aid the fusing process. For tinned copper tubes, some of the inside tin layer flows to wet copper surfaces and dissolve copper impurities. Some tin flows to seal small spaces between the fused wires. Some of the tin on the outside surface and inside surface of the tube may vaporize.

Abstract: Apparatus is provided for sensing a location on a commutator and, in response thereto, actuating a tool for performing an operation on the commutator. The apparatus includes a device for mounting the commutator for rotation so that it may be indexed to successive commutator bars which are to be worked on. There is also a light source and a device for directing light from the source to the surface of the commutator, and a device for directing the reflection of light from the commutator surface to a sensing device. When the light beam impinges on a non-reflective area of the commutator so that the sensing device is not actuated, the sensing device signals a control circuit for stopping the rotation of said commutator and for actuating a tool for performing an operation on the commutator. In order to prevent the interference of ambient light with the operation of the sensing apparatus, a protective housing is provided for at least partially enclosing the light-directing devices.

Abstract: Apparatus for controlling the quality of a joint between electric motor armature wires and corresponding commutator bars is disclosed, including means for heating the armature wires and the commutator bars at the points where they are to be joined, means for bringing the armature wires and commutator bars into contact with the means for heating them, fiber optic means for determining the temperature at a point relative to said joint by collecting the radiant energy emitted from that point, means for converting the radiant energy into a usable electronic signal, and means for terminating the means for heating the armature wires and commutator bars in response to said electronic signal when the temperature at that joint reaches a predetermined temperature.

Abstract: An electrical tang type terminal for use in fusing aluminum or aluminum alloy wire thereto. The terminal includes an enlargement to absorb part of the active electrode pressure during heat and pressure application, thereby peventing shearing or undue weakening of the softened wire. Prior to fusing, the enlargement is spaced from the opposite portion of the tang or body to which it is to be fused to permit localized heating and some wire deformation. During fusing, the enlargement helps control the mechanical pressure on the softened wire.

Abstract: A machine and method terminating armature windings to commutators having means for testing the integrity of the connection and winding between two commutator segments immediately after each termination is bonded and recycling the bonding sequence at the same or different bonding energy if certain faults are detected. If the tests indicate certain faults or retests are negative, the armature is ejected without making further termination.