The disclosure discloses a novel arched commutator structure of a brush direct current motor, which comprises a round nut or a bolt, a pressing ring, a reinforcing ring, a sleeve, a commutator segment group and a mica ring. The effective part of the arched commutator is the commutator segment group consisting of commutator segments with V-shaped gaps at two ends and mica sheets; and the V-shaped groove of the commutator segment group is clamped by the V-shaped cone part of the pressing ring at one end and the V-shaped cone part of the sleeve at the other end. The advantages are: the deformation of the commutator caused by various acting forces generated in the operation process of the motor can be reduced and even prevented; the economic benefit generated every year cannot be estimated by taking a hundred million as a unit; materials are saved; the production cost is reduced.

The present disclosure relates to a method and system for manufacturing a motor in which noise and current ripple caused by mechanical friction between a brush and a commutator have been reduced. In detail, a motor manufacturing method of the present disclosure comprises the steps of: assembling a shaft, an armature fixed on the shaft to be rotatably arranged, a commutator fixed on the shaft to rotate together with the armature, and a brush contacting a portion of the surface of the commutator; applying a voltage to the brush and rotating the armature and the commutator together through the rotation of the shaft to age the surface of the commutator; and, in a magnetizing device, connecting a case including a magnetized magnet to the assembled shaft, armature, commutator, and brush.

The present disclosure relates to a method and system for manufacturing a motor in which noise and current ripple caused by mechanical friction between a brush and a commutator have been reduced. In detail, a motor manufacturing method of the present disclosure comprises the steps of: assembling a shaft, an armature fixed on the shaft to be rotatably arranged, a commutator fixed on the shaft to rotate together with the armature, and a brush contacting a portion of the surface of the commutator; applying a voltage to the brush and rotating the armature and the commutator together through the rotation of the shaft to age the surface of the commutator; and, in a magnetizing device, connecting a case including a magnetized magnet to the assembled shaft, armature, commutator, and brush.

An electrical contact device includes a high electric potential-side contact and a low electric potential-side contact having a lower electric potential than the high electric potential-side contact. The high electric potential-side contact and the low electric potential-side contact are configured to be brought into and out of contact with each other. At least one of the high electric potential-side contact and the low electric potential-side contact is formed of a low-boiling point material whose boiling point is lower than 2562° C. or a mixed material that contains the low-boiling point material.

An electrical contact device includes a high electric potential-side contact and a low electric potential-side contact having a lower electric potential than the high electric potential-side contact. The high electric potential-side contact and the low electric potential-side contact are configured to be brought into and out of contact with each other. At least one of the high electric potential-side contact and the low electric potential-side contact is formed of a low-boiling point material whose boiling point is lower than 2562° C. or a mixed material that contains the low-boiling point material.

The invention relates to a commutator, comprising an insulating base and a plurality of commutator segments arranged on the insulating base, wherein each commutator segment comprises a metal layer, a transition layer and a graphite layer arranged on the base in sequence. The transition layer contains a material identical to that of the graphite layer and a material identical to that of the metal layer. The invention further relates to a motor comprising the commutator and a method for manufacturing the commutator. As the transition layer contains the material identical to that of the graphite layer and the metal layer, the problem that the graphite layer and the metal layer are cracked during high temperature sintering is resolved. The service life of the commutator is prolonged. The method for manufacturing the commutator reduces chemical contamination and production cost caused by electroplating and brazing used in a traditional technology.

A bus bar engaged with each brush holder and electrically connected to positive brushes. A rotor has coils and protrusions extending in an outward direction and electrically connecting the coils to commutator segments. Each brush portion end surface faces the outward direction, the bus bar has an engagement portion with an end facing the inward direction, and the end of the engagement portion is further in the outward direction than the end surface portion. The brush has an end facing the first direction, the bus bar has an end facing a second direction, and the end of the bus bar is further in the second direction than the end of the brush facing the first direction. Each protrusion end faces the second direction, and the end of the bus bar facing the first direction is further in the second direction than the end of the protrusion facing the second direction.

A bus bar engaged with each brush holder and electrically connected to positive brushes. A rotor has coils and protrusions extending in an outward direction and electrically connecting the coils to commutator segments. Each brush portion end surface faces the outward direction, the bus bar has an engagement portion with an end facing the inward direction, and the end of the engagement portion is further in the outward direction than the end surface portion. The brush has an end facing the first direction, the bus bar has an end facing a second direction, and the end of the bus bar is further in the second direction than the end of the brush facing the first direction. Each protrusion end faces the second direction, and the end of the bus bar facing the first direction is further in the second direction than the end of the protrusion facing the second direction.

A direct-current motor commutator structure includes: a commutator base, comprising a front pressing ring, a pressing plate and a sleeve that are sequentially abutted, a sealing ring being provided between the front pressing ring and the pressing plate, and between the pressing plate and the sleeve constituting a bearing area; a commutator, mounted in the bearing area and having opposite first and second portions; a sealing element being potted or provided between the second portion and the sleeve; an equalizing cable, mounted on an outer side of a first potting area formed by the first portion, the pressing plate and the front pressing ring, abutting against the first portion and the front pressing ring, and covering the first potting area; and an armature coil, clinging to the equalizing cable and located on an outer side of a second potting area formed by the equalizing cable and the front pressing ring.

A direct-current motor commutator structure includes: a commutator base, comprising a front pressing ring, a pressing plate and a sleeve that are sequentially abutted, a sealing ring being provided between the front pressing ring and the pressing plate, and between the pressing plate and the sleeve constituting a bearing area; a commutator, mounted in the bearing area and having opposite first and second portions; a sealing element being potted or provided between the second portion and the sleeve; an equalizing cable, mounted on an outer side of a first potting area formed by the first portion, the pressing plate and the front pressing ring, abutting against the first portion and the front pressing ring, and covering the first potting area; and an armature coil, clinging to the equalizing cable and located on an outer side of a second potting area formed by the equalizing cable and the front pressing ring.