Commu tator Fusing

Joyal Products, Incorporated

P.O. Box 1187 – Linden, New Jersey 07036 – USA
908-486-6100 – FAX 908-486-6013 – E-Mail: [email protected]

The Commutator Connection (347 K) provides a detailed description of the Commutator Fusing process and the Commutator Brazing process. Also mentioned is the difference between fusing and welding, fusing/brazing electrodes and electrode dressing, as well as quality control methods and SPC for fusing and brazing.

Below are three charts, in Adobe’s Acrobat file format, which provide commutator slotting and commutator tang dimensions in different wire dimensioning systems.

An explanation of the commutator tang and slotting charts for Commutator Fusing that are listed below.

Commutator Tang and Slotting Charts (232 K) in American Wire Gauge (AWG)

Commutator Tang and Slotting Charts (328 K) in Metric Wire Size

Commutator Tang and Slotting Charts (240 K) in the British Standard Wire Gauge (SWG)

The above charts supply data which do not take into account wire insulation, electrode design, or commutator design, as well as other variables. For specific commutator – insulation – electrode – wire combinations, please consult Joyal.

Slope Control offers many advantages when fusing. Up-Slope provides a cushioned heat to properly seat the fusing electrodes prior to maximum energy being applied. Down-Slope provides an annealing heat after welding has occurred. This paper describes both functions for AC and DC fusing.

Tungsten Fusing Electrodes describes the material used to produce Commutator Fusing electrodes. Highlighted is the health problem associated with radioactive Thoriated Tungsten, when used for fusing electrodes. There is also a discussion of a special Tungsten alloy formulated especially for use as fusing electrodes, and a method of diamond dressing fusing electrodes.

The Carbon Commutator – This is a technical paper that discusses DC and/or Universal Motors that use Commutators that have a brush track that is made of Carbon or Graphite. This paper does not directly cover Commutator Fusing of armatures with Carbon Commutators, other than a very brief discussion of the subject. The paper discusses the history and development of the carbon commutators and motors that use Carbon Commutators, and the use in the future, of motors with Carbon Commutators.

Briefly, the advantage of using motors with Carbon Commutators is that they have an extremely long brush life, so long that the motor’s bearings would fail prior to the commutator or brushes. Because of their long life, these types of motors could be used to replaced much more expensive induction motors.

Statistical Process Control (SPC) Overview. These files show computer output screens, as well as other information, on data collection and data analysis using SPC techniques for monitoring the Commutator Fusing, Resistance Welding, and Wire Fusing processes. To properly monitor these processes, a correct choice must be made of what data combinations, from the process, must be collected. This SPC Overview provides some understanding of the use of SPC for these processes.

Commutator Fusing SPC Overview for Windows (1.2 MB) for use with a computer using Windows-95/98 (32K) or Windows-3.1 (16K).
  To install this overview, down load the file, From windows:
     Select RUN from the Program Manager File Menu.
     [For Windows-95/98 select RUN from the Start Menu]
     Type a:spcsetup (or b:spcsetup) and press <enter>
     Follow the on-screen instructions
     Double click Joyal’s SPC Software Overview

Commutator Fusing SPC Overview for the Macintosh (842 K) for use with a Macintosh Computer
  To install this overview, down load the file:
     Double click Joyal’s SPC Software Overview

Fusing and SPC describes some very basic principles of SPC, and Six Sigma that are used to monitor and possibly control the Fusing process. This paper covers Commutator Fusing, SN-Fusing and Tang Fusing, The principles described could also apply to Commutator and Resistance Brazing and possibly Spot Welding.

To obtain an Adobe Acrobat reader click on the “Get Acrobat” icon  

The MSDS (Material Safety Data Sheets) Page where MSDS are available for materials that Joyal offers, and for which these sheets are required. These MSDS are in the Adobe Arcobat format. You must use an Adobe Acrobat reader to view this data. Acrobat readers are available from Adobe’s WWW Site for the following computers: DOS;   Windows; Macintosh ;  UNIX. These is a down-loadable link for these readers on the MSDS page.