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: 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: 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: A fusing apparatus and method is described for forming a fuse joint between an armature wire having electrical insulation thereon and a terminal extending from a commutator bar. The apparatus includes a U-shaped fusing electrode including a central portion having an effective electrical resistance higher than the remaining portions of the electrode. By applying current through the electrode, the central portion is heated to a temperature higher than the remaining portions of the electrode sufficient to remove the electrical insulation from the armature wire and to fuse the armature wire to the terminal.

Abstract: An electrode set for a fusing apparatus includes a first electrode and a second electrode each having concave shaped end faces formed from cylindrical openings. The electrode set provides enhanced fusing of magnet wire circumferentially about a terminal pin of, for example, a coiled bobbin. The heat generated during the fusing process melts the insulation on the magnet wire to permit the fusing of the wire circumferentially to the pin.

Abstract: Fusing apparatus and methods for fusing armature wires having an electrically insulating coating to the tangs of a commutator include a pair of spaced apart, side-by-side electrodes. The electrode pair are cojointly brought to bear on a common tang surface overlying an armature wire to be fused. The heat generated during the fusing process vaporizes the insulation on the armature wire to permit the fusing of the wire to the tang under controlled conditions.

Abstract: Electrical bonding apparatus such as a fusing machine is provided with plural separate electrode holders such that the position of an electrode relative to each holder can be adjusted. The position of each electrode relative to the holder is adjusted while the holder is detached from the machine, and while other holders and electrodes are in place on the machine. Thus, the machine can be provided with a new electrode preadjusted to the desired position by interchanging electrode holders. An electrode changer on the fusing machine may include a frame and a movable retaining element adapted to hold several electrodes at different stations. Electrical transmission elements such as brushes on the retaining element and frame may be biased against one another to provide an electrically conductive path, and this bias may be released upon movement of the retaining element relative to the frame so as to avoid wear of the electrical transmission elements.

Abstract: A terminal pin is provided with a widened connecting section defining shoulders on the terminal so that the terminal serves as a standoff to support a device such as a coil remote from a circuit board. The terminal preferably is provided with ridges and grooves. The ridges have sloping surfaces which guide a wire into the grooves during assembly of a wire to the terminal. The surfaces bordering the grooves are adapted for frictional locking engagement with the wire. The wire can be fused to the terminal by a solderless fusing process. The ridges protect the wire from damage by the fusing electrodes, and deformation of the ridges preferably serves to lock the wire into the grooves. Preferably, the wire-receiving grooves are formed in the widened connecting section.

Abstract: Fusing apparatus is provided with a fusing electrode holder for holding one or more fusing electrodes defining a plurality of fusing contact regions. One fusing contact region is repeatedly engaged with successive workpieces, such as electric motor rotors, to fuse elements of each workpiece. The apparatus is provided with a shifting device for mechanically moving the fusing electrode holder to present a new fusing contact surface region, preferably after a predetermined number of cycles. Preferably, the ground electrode holder is also shifted to present a new ground contact region. Because the contact regions are renewed, productivity and quality will not be affected by electrode wear. The fusing electrode holder may be a rotatable turret having radial holes for receiving rod-like fusing electrodes, the turret being rotated to swing a new fusing electrode into position on each change cycle.

Abstract: A fusing machine and method employ a first electrode which defines a fusing station and a second electrode which is movable toward and away from the first electrode. Two wires which have been fused together at the fusing station are automatically cut without removing the fused wires from the fusing station prior to cutting them. Also disclosed is an electrode set including a first electrode having an inwardly tapered slot sized and shaped so as to releaseably capture wires to be fused and a second electrode having a straight-sided tip sized and shaped so as to be freely movable into and out of the slot in the first electrode.

Abstract: A terminal pin of a coil bobbin has opposed sets of notches sized, shaped and spaced so as to permit magnet wire to be wrapped around the terminal pin in a spiral path defined by the notches. Because the magnet wire is received in the notches, the notches function to properly locate the wire on the pin and to maintain the wire stationary. The notches have a depth selected so that the portions of the magnet wire received in the notches are recessed below an outer surface of the pin, whereby electrodes used to fuse the magnet wire to the pin are allowed to contact the pin and thereby form a closed circuit. The resulting heat melts the insulation on the magnet wire to permit the fusing of the wire to the pin.

Abstract: A fusing machine and method employ a first electrode which defines a fusing station and a second electrode which is movable toward and away from the first electrode. Two wires which have been fused together at the fusing station are automatically cut without removing the fused wires from the fusing station prior to cutting them. Also disclosed is an electrode set including a first electrode having an inwardly tapered slot sized and shaped so as to releasably capture wires to be fused and a second electrode having a straight-sided tip sized and shaped so as to be freely movable into and out of the slot in the first electrode.

Abstract: A fusing machine utilizes a fusing electrode assembly and a ground electrode assembly suspended from the fusing electrode assembly. The fusing electrode assembly includes a lower fusing electrode shaft and an upper fusing electrode shaft. The lower fusing electrode shaft has an open end adapted to receive the upper fusing electrode shaft and a compression spring interposed between the shafts. An adjustable stop is threaded onto the upper fusing electrode shaft to limit the downward movement of the upper fusing electrode shaft. The lower fusing electrode shaft is keyed to a fusing electrode holder formed from a plurality of keyed members. The ground electrode assembly includes an adjusting mechanism, whereby the position of a ground electrode carried by the ground electrode assembly can be adjusted relative to a fusing electrode carried by the fusing electrode assembly. The fusing electrode assembly and the ground electrode assembly are mounted to a frame which is adjustably attached to a supporting structure.

Abstract: A fusing machine utilizes a fusing electrode assembly and a ground electrode assembly suspended from the fusing electrode assembly. The fusing electrode assembly includes a lower fusing electrode shaft and an upper fusing electrode shaft. The lower fusing electrode shaft has an open end adapted to receive the upper fusing electrode shaft and a compression spring interposed between the shafts. An adjustable stop is threaded onto the upper fusing electrode shaft to limit the downward movement of the upper fusing electrode shaft. The lower fusing electrode shaft is keyed to a fusing electrode holder formed from a plurality of keyed members. The ground electrode assembly includes an adjusting mechanism, whereby the position of a ground electrode carried by the ground electrode assembly can be adjusted relative to a fusing electrode carried by the fusing electrode assembly. The fusing electrode assembly and the ground electrode assembly are mounted to a frame which is adjustably attached to a supporting structure.

Abstract: A method and apparatus for brazing a commutator to a pair of armature wires which are arranged one above the other employ a dual brazing alloy wire feeder which feeds one brazing alloy wire between a commutator and the lowermost armature wire, while simultaneously feeding the other brazing alloy wire between the lowermost armature wire and the uppermost armature wire. At the conclusion of the brazing operation, the partially consumed brazing alloy wires are automatically advanced to a predetermined length in preparation for a subsequent brazing operation by which the commutator is mechanically and electrically connected to another pair of armature wires.

Abstract: A fusing machine utilizes a fusing electrode assembly and a ground electrode assembly suspended from the fusing electrode assembly. The fusing electrode assembly includes a lower fusing electrode shaft and an upper fusing electrode shaft. The lower fusing electrode shaft has an open end adapted to receive the upper fusing electrode shaft and a compression spring interposed between the shafts. An adjustable stop is threaded onto the upper fusing electrode shaft to limit the downward movement of the upper fusing electrode shaft. The lower fusing electrode shaft is keyed to a fusing electrode holder formed from a plurality of keyed members. The ground electrode assembly includes an adjusting mechanism, whereby the position of a ground electrode carried by the ground electrode assembly can be adjusted relative to a fusing electrode carried by the fusing electrode assembly. The fusing electrode assembly and the ground electrode assembly are mounted to a frame which is adjustably attached to a supporting structure.

Abstract: A fusing machine utilizes a fusing electrode assembly and a ground electrode assembly suspended from the fusing electrode assembly. The fusing electrode assembly includes a lower fusing electrode shaft and an upper fusing electrode shaft. The lower fusing electrode shaft has an open end adapted to receive the upper fusing electrode shaft and a compression spring interposed between the shafts. An adjustable stop is threaded onto the upper fusing electrode shaft to limit the downward movement of the upper fusing electrode shaft. The lower fusing electrode shaft is keyed to a fusing electrode holder formed from a plurality of keyed members. The ground electrode assembly includes an adjusting mechanism, whereby the position of a ground electrode carried by the ground electrode assembly can be adjusted relative to a fusing electrode carried by the fusing electrode assembly. The fusing electrode assembly and the ground electrode assembly are mounted to a frame which is adjustably attached to a supporting structure.

Abstract: The present invention provides a method and apparatus for controlling the amount of heat energy supplied by a bonding transformer to coil windings to heat the windings to a predetermined temperature level for fusing the windings into an integral mass. This is accomplished by continuously monitoring the current level in the secondary windings of the bonding transformer and comparing the signal produced with a signal preset in a comparator, which preset signal corresponds to the heat energy required by the coil windings to heat them to the predetermined temperature level. The comparator then operates to deactivate the bonding transformer when the monitored signal corresponds to the predetermined temperature level desired in the coil windings.