ELECTRIC MACHINE AND A METHOD OF CONSTRUCTING A COMMUTATOR FOR AN ELECTRIC MACHINE
An electric machine and a method of forming a commutator for an electric machine includes forming a commutator assembly including a plurality of commutator bar members linked through a corresponding plurality of bridge elements, rolling the commutator assembly into a commutator form having a substantially continuous, uninterrupted, outer surface, introducing an internal support member that receives an end portion of each of the plurality of commutator bar members into an inner diameter of the commutator form, and separating the plurality of commutator bar members by removing each of the plurality of bridge elements creating a discontinuous outer surface.
1 . A method of constructing a commutator for an electric machine, the method comprising:
forming a one-piece commutator assembly including a plurality of commutator bar members linked through a corresponding plurality of bridge elements;
rolling the one-piece commutator assembly into a commutator form having a substantially continuous, uninterrupted, outer surface;
introducing an internal support member that receives an end portion of each of the plurality of commutator bar members into an inner diameter of the commutator form; and
separating the plurality of commutator bar members by removing each of the plurality of bridge elements creating a discontinuous outer surface.
2 . The method of claim 1 , wherein introducing the internal support includes molding the internal support about the end portion of each of the plurality of commutator bar members.
3 . The method of claim 1 , further comprising, forming a circumferential notch in the commutator form.
4 . The method of claim 3 , wherein forming the circumferential notch in the commutator form includes forming the circumferential notch in the substantially continuous, uninterrupted outer surface of the commutator form.
5 . The method of claim 4 , further comprising: wrapping the commutator form with a fiberglass tape.
6 . The method of claim 5 , wherein wrapping the commutator form with fiberglass tape includes positioning the fiberglass tape in the circumferential notch.
7 . The method of claim 1 , further comprising, bending an axial end of each of the plurality of commutator bar members to form a riser.
8 . The method of claim 7 , wherein bending the axial end of each of the plurality of commutator bar members to form the riser includes forming a substantially right angle bend in the axial end of each of the plurality of commutator bar members.
9 . The method of claim 7 , further comprising: forming a slot in an end portion of each of the plurality of commutator bar members.
10 . The method of claim 9 , wherein forming the slot includes forming a slot in the axial end of each of the plurality of commutator bar members.
11 . An electric machine including an armature having a commutator constructed by a method comprising:
forming a one-piece commutator assembly including a plurality of commutator bar members linked through a corresponding plurality of bridge elements;
rolling the one-piece commutator assembly into a commutator form having a substantially continuous, uninterrupted, outer surface;
introducing an internal support member that receives an end portion of each of the plurality of commutator bar members into an inner diameter of the commutator form; and
separating the plurality of commutator bar members by removing each of the plurality of bridge elements creating a discontinuous outer surface.
12 . The electric machine according to claim 11 , wherein introducing the internal support includes molding the internal support about the end portion of each of the plurality of commutator bar members.
13 . The electric machine according to claim 11 , further comprising, forming a circumferential notch in the commutator form.
14 . The electric machine according to claim 13 , wherein forming the circumferential notch in the commutator form includes forming the circumferential notch in the substantially continuous, uninterrupted outer surface of the commutator form.
15 . The electric machine according to claim 14 , further comprising: wrapping the commutator form with a fiberglass tape.
16 . The electric machine according to claim 15 , wherein wrapping the commutator form with fiberglass tape includes positioning the fiberglass tape in the circumferential notch.
17 . The electric machine according to claim 11 , further comprising, bending an axial end of each of the plurality of commutator bar members to form a riser.
18 . The electric machine according to claim 17 , wherein bending the axial end of each of the plurality of commutator bar members to form the riser includes forming a substantially right angle bend in the axial end of each of the plurality of commutator bar members.
19 . The electric machine according to claim 17 , further comprising: forming a slot in an end portion of each of the plurality of commutator bar members.
20 . The electric machine according to claim 19 , wherein forming the slot includes forming the slot in the axial end of each of the plurality of commutator bar members.