Gm Global Technolgoy Operations, Inc.

Delco Remy America, Inc.

Frank D Sorg

Ronald Dale Gentry

James A Spellman

Jeffrey L Mummert

The method of the present invention involves setting a penetration threshold as well as a maximum weld time when hot staking armature conductors to the slots of a commutator. To perform each weld, an electrode is forcibly contacted with the top conductor in one of the slots of the commutator. Next, electric current is delivered to the electrode, causing the conductor to heat and begin to deform within the slot. During this time, the electrode moves further into the slot. If the electrode reaches the penetration threshold in the commutator slot before the maximum weld time is reached, current to the electrode is terminated. After terminating current to the electrode, the electrode remains in contact with and applies force to the conductor until the maximum weld time is reached. After the maximum weld time is reached, the electrode is removed from contact with welded conductor.

Dynamic weld power termination for hot-staking armature commutators

A brush holder assembly for a dynamoelectric machine. The assembly comprises an annular metallic support plate that carries a plurality of metallic brush holders. Each brush holder slidably supports a brush. Two of the brush holders have tangs that extend from a respective brush holder. A bus bar formed of copper is welded to the tangs to thereby support the bus bar from the brush holders. The brushes that are associated with the two brush holders are each connected to a brush conductor. The brush conductors are welded to the bus bar. Another conductor or lead is welded to the bus bar to feed current to the bus bar.

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Middletown, IN, United States of America

Frank D Sorg