WO2001079824A1 - Method and apparatus for testing commutators - Google Patents
Method and apparatus for testing commutators Download PDFInfo
- Publication number
- WO2001079824A1 WO2001079824A1 PCT/US2001/012277 US0112277W WO0179824A1 WO 2001079824 A1 WO2001079824 A1 WO 2001079824A1 US 0112277 W US0112277 W US 0112277W WO 0179824 A1 WO0179824 A1 WO 0179824A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- commutator
- commutators
- temperature
- speed
- substantially constant
- Prior art date
Links
Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/002—Thermal testing
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/34—Testing dynamo-electric machines
Definitions
- This invention relates to methods and apparatus for testing, qualifying and/or evaluating the performance capabilities and/or characteristics of commutators.
- This invention provides methods and apparatus for testing, qualifying and/or evaluating the performance capabilities and/or characteristics of commutators wherein a commutator is preheated to a first predetermined temperature, held at a substantially constant temperature, and rotated at increasing speeds until the commutator fails.
- additional and substantially comparable commutators are preheated to the same predetermined temperature and rotated at increasing speeds until they fail.
- the data from these tests establish a predictable range of speeds at which this commutator can be expected to operate satisfactorily at this temperature.
- Additional commutators are preheated to higher temperatures and rotated at increasing speeds, while held at these temperatures, until they fail.
- the tests can be performed rapidly and economically, and are suitable for almost any type of commutator design.
- this invention enables commutator and motor designers to design, select and modify commutators for a wide range of motor designs.
- Figure 1 is a schematic representation of one form of apparatus embodying this invention.
- Figure 2 is an enlarged cross-sectional view of a support for commutators in the apparatus of Figure 1.
- FIG. 3 is a typical graph of the results produced by the methods and apparatus of this invention. Detailed Description
- Figure 1 illustrates one test system embodying this invention. Tests are performed in a chamber, generally referred to as 10, with a cylindrical lower section 11 and a upper section 13 in the form of a truncated cone with a open top 15. Lower section 11 is lined with lead or another impact absorbing material 21 to prevent damage from fragments of bursting commutators, and contains a central, tubular opening 17 with a glass plate 19 mounted therein, through which commutator failures can be observed and recorded.
- a chamber generally referred to as 10
- Lower section 11 is lined with lead or another impact absorbing material 21 to prevent damage from fragments of bursting commutators, and contains a central, tubular opening 17 with a glass plate 19 mounted therein, through which commutator failures can be observed and recorded.
- a flexible support wire or rod 29 depends from a chuck 27 on the lower end of motor 25.
- the commutator C to be tested is supported on the lower portion of wire 29 by a support, generally referred to as 30, which is illustrated in Figure 2.
- a support generally referred to as 30, which is illustrated in Figure 2.
- Several supports are provided so that commutators of different sizes can be tested.
- Each support has a central shaft 31 that extends through the commutator C to be tested.
- the outer diameter of shaft 31 is .0005" to .0010" smaller than the central bore of the commutator.
- the commutator is held on shaft 31 by a shoulder 33 on the upper portion of the shaft, and an adjusting nut 35 that is threaded onto the lower end of the shaft.
- the support wire or rod 29 extends into shaft 31, and the shaft is secured to the support wire or rod 29 with a set screw 37.
- Support wire 29 must be stiff enough to prevent excessive movement of commutator C as the commutator is accelerated by motor 31 , but flexible enough to allow the commutator to balance itself, and to protect the shaft and bearings of motor 25 by absorbing vibrations when a commutator bursts.
- the commutator under test is preferably surrounded by a sensing wire 41 positioned about 0.25 inche from the commutator, when mounted in support 30 but at rest. This allows the commutator to move far enough from the central axis to balance the system, while the commutator remains intact, but positions the sensing wire 41 to reliably detect commutator failures.
- commutators When commutators fail in a centrifugal, thermo dynamic test such as this, failure usually occurs in a "burst" or loss of one or more parts of the commutator.
- the commutating elements i.e., the bars which are spaced around the periphery of cylindrical commutators such as the one illustrated in Figure 2, or the pie-shaped segments that are attached to one end of face commutators, are the parts that are most likely to fail.
- Sensing wire 41 is placed so that flying pieces will strike the wire 41 when they are thrown from the commutator as the commutator fails.
- a movement sensor 43 such as a proximity sensor, laser sensor, magnet or electrical contact detects movement of sensing wire 41 and triggers a controller 45 for a high speed camera 47, positioned beneath glass plate 19, which records the failure of the commutator.
- the temperature of commutator C is controlled during a test by one or more heaters 51 mounted near the top of the upper section 13 of test chamber 10.
- the temperature is monitored by one or more temperature gauges 53, also mounted near the top of the upper section of the test chamber.
- the temperature gauge(s) are preferably infrared gauges such as the Model No. SXSMTCF2L2 from Kirk Company of Berea, Ohio. These gauges can provide an indication of the commutator temperature which is accurate to within 6°F.
- Temperature controller 53 controls heater(s) 51. With heaters 51 and infrared temperature gauges, temperature controller 55 can reliably maintain the temperature of the commutator C under test within 6°F degrees of the desired level.
- temperature-speed interface controllers 57 signals motor controller 59 to accelerate the rotation of the commutator C at a controlled rate, normally between about 100 and about 200 RPM/sec.
- a test or qualification of a particular commutator is initiated by supporting one of these commutators upon wire 29, as illustrated in Figure 2, and preheating the commutator to a predetermined temperature, such as 100°F.
- a predetermined temperature such as 100°F.
- the commutator is rotated slowly, e.g., at about 100 to 200 RPM, to ensure even heating.
- motor controller 59 gradually and steadily increases the speed of motor 31, typically at a rate of about 100 to 200 RPM per sec, and, until the commutator bursts or otherwise fails structurally in a manner that dislodges commutator bars, face segments or other pieces that move sensing wire 41.
- the first picture can be taken within 10 milliseconds following the first contact with sensing wire 41.
- Modern high speed cameras can take additional pictures at a rate of 8,000 frames per second or more.
- this system provides valuable information that can be used to improve the design and prevent future failures.
- the test as described above is then repeated with several identical or substantially equivalent commutators to provide a set of data points for the failure speed for this commutator at this temperature.
- commutators typically 3 to 5 commutators may be tested at each temperature, and the failure speeds for the individual tests are averaged or otherwise adjusted to provide a composite speed/temperature data point.
Abstract
Methody and apparatus for testing, qualifying and/or evaluating the performance capabilities and/or characteristics of commutators are disclosed. A commutator (C) is preheated, using a heater (51), to a first predetermined temperature, held at a substantially constant temperature, and rotated at increasing speeds, by means of a variable speed motor (25) until the commutator (C) fails. Additional and substantially comparable commutators are preheated to the same predetermined temperature and rotated at increasing speeds until they fail. Additional commutators are preheated to higher temperatures and rotated at increasing speeds, while held at these temperatures, until they fail. Speed/temperature failure data from these tests provide a graph that enables designers to determine appropriate speed and temperature ranges for commutators over a wide range of applications.
Description
METHOD AND APPARATUS FOR TESTING COMMUTATORS
Technical Field
This invention relates to methods and apparatus for testing, qualifying and/or evaluating the performance capabilities and/or characteristics of commutators.
Background Commutator and motor designers are regularly faced with a number of difficult questions, including:
• Can the commutator handle the design speed?
• Can the commutator handle the anticipated surface temperature?
• The motor load is oscillating. Temperature and speed are changing non-linearly. How will the commutator perform in this "thermal- dynamic chaos"?
• Did the motor designer make the right decision for a brush- commutator cooling system?
• Did the commutator manufacturer over design the commutator for this application, and create unnecessary cost for the manufacturer and customer?
• Will a sample commutator fail a customer life-test, thereby losing potential sales and damaging the manufacturer's reputation?
• A major designer wants to add more power to a motor using the same commutator. Can the commutator manufacturer make the right recommendation?
There are many mathematical models and test methods to address one or more of these questions. However, there are no current tests which will allow a
commutator or motor manufacturer to determine the suitability of various commutators for particular applications rapidly and accurately.
Summary of the Invention
This invention provides methods and apparatus for testing, qualifying and/or evaluating the performance capabilities and/or characteristics of commutators wherein a commutator is preheated to a first predetermined temperature, held at a substantially constant temperature, and rotated at increasing speeds until the commutator fails.
Preferably, additional and substantially comparable commutators are preheated to the same predetermined temperature and rotated at increasing speeds until they fail. The data from these tests establish a predictable range of speeds at which this commutator can be expected to operate satisfactorily at this temperature. Additional commutators are preheated to higher temperatures and rotated at increasing speeds, while held at these temperatures, until they fail. Speed/temperature failure data from these tests provide a graph that enables designers = to determine appropriate speed and temperature ranges for commutators over a wide range of applications. The tests can be performed rapidly and economically, and are suitable for almost any type of commutator design. Thus, this invention enables commutator and motor designers to design, select and modify commutators for a wide range of motor designs.
Other features and advantages of this invention will be apparent from the following detailed description.
Drawings Figure 1 is a schematic representation of one form of apparatus embodying this invention.
Figure 2 is an enlarged cross-sectional view of a support for commutators in the apparatus of Figure 1.
Figure 3 is a typical graph of the results produced by the methods and apparatus of this invention. Detailed Description
Figure 1 illustrates one test system embodying this invention. Tests are performed in a chamber, generally referred to as 10, with a cylindrical lower section 11 and a upper section 13 in the form of a truncated cone with a open top 15. Lower section 11 is lined with lead or another impact absorbing material 21 to prevent damage from fragments of bursting commutators, and contains a central, tubular opening 17 with a glass plate 19 mounted therein, through which commutator failures can be observed and recorded.
A variable speed motor 25, capable of speeds up to about 100,000 rpm, is mounted above or slightly inside the open top 15 of container 10. The speed of the motion is governed by a motor controller 59. A flexible support wire or rod 29 depends from a chuck 27 on the lower end of motor 25. The commutator C to be tested is supported on the lower portion of wire 29 by a support, generally referred to as 30, which is illustrated in Figure 2. Several supports are provided so that commutators of different sizes can be tested. Each support has a central shaft 31 that extends through the commutator C to be tested. Preferably, to help ensure smooth operation, the outer diameter of shaft 31 is .0005" to .0010" smaller than the central bore of the commutator. The commutator is held on shaft 31 by a shoulder 33 on the upper portion of the shaft, and an adjusting nut 35 that is threaded onto the lower end
of the shaft. The support wire or rod 29 extends into shaft 31, and the shaft is secured to the support wire or rod 29 with a set screw 37.
Support wire 29 must be stiff enough to prevent excessive movement of commutator C as the commutator is accelerated by motor 31 , but flexible enough to allow the commutator to balance itself, and to protect the shaft and bearings of motor 25 by absorbing vibrations when a commutator bursts. When a commutator rotates, it will balance itself by orbiting in a small circle about the central axis of support wire 29. To accommodate this motion, the commutator under test is preferably surrounded by a sensing wire 41 positioned about 0.25 inche from the commutator, when mounted in support 30 but at rest. This allows the commutator to move far enough from the central axis to balance the system, while the commutator remains intact, but positions the sensing wire 41 to reliably detect commutator failures.
When commutators fail in a centrifugal, thermo dynamic test such as this, failure usually occurs in a "burst" or loss of one or more parts of the commutator. The commutating elements, i.e., the bars which are spaced around the periphery of cylindrical commutators such as the one illustrated in Figure 2, or the pie-shaped segments that are attached to one end of face commutators, are the parts that are most likely to fail. Sensing wire 41 is placed so that flying pieces will strike the wire 41 when they are thrown from the commutator as the commutator fails. A movement sensor 43, such as a proximity sensor, laser sensor, magnet or electrical contact detects movement of sensing wire 41 and triggers a controller 45 for a high speed camera 47, positioned beneath glass plate 19, which records the failure of the commutator.
The temperature of commutator C is controlled during a test by one or more heaters 51 mounted near the top of the upper section 13 of test chamber 10. The temperature is monitored by one or more temperature gauges 53, also mounted near the top of the upper section of the test chamber. The temperature gauge(s) are preferably infrared gauges such as the Model No. SXSMTCF2L2 from Kirk Company of Berea, Ohio. These gauges can provide an indication of the commutator temperature which is accurate to within 6°F.
Signals from the temperature gauge(s) 53 are supplied to a temperature controller 55 and to a temperature-speed interface controller 57. Temperature controller 53 controls heater(s) 51. With heaters 51 and infrared temperature gauges, temperature controller 55 can reliably maintain the temperature of the commutator C under test within 6°F degrees of the desired level. When the temperatures reach a preset level, temperature-speed interface controllers 57 signals motor controller 59 to accelerate the rotation of the commutator C at a controlled rate, normally between about 100 and about 200 RPM/sec.
A test or qualification of a particular commutator is initiated by supporting one of these commutators upon wire 29, as illustrated in Figure 2, and preheating the commutator to a predetermined temperature, such as 100°F. Preferably the commutator is rotated slowly, e.g., at about 100 to 200 RPM, to ensure even heating. When the commutator has reached the desired temperature, as determined by temperature gauge 53, motor controller 59 gradually and steadily increases the speed of motor 31, typically at a rate of about 100 to 200 RPM per sec, and, until the commutator bursts or otherwise fails structurally in a manner that dislodges commutator bars, face segments or other pieces that move sensing wire 41. This is
detected by sensor 43, and the strobe and camera controller 45 cause camera 47, with the assistance of strobe lights 49, to take a series of pictures of the failing commutator. With the illustrated system the first picture can be taken within 10 milliseconds following the first contact with sensing wire 41. Modern high speed cameras can take additional pictures at a rate of 8,000 frames per second or more. In addition to providing data for the qualification of the commutator, this system provides valuable information that can be used to improve the design and prevent future failures.
The test as described above is then repeated with several identical or substantially equivalent commutators to provide a set of data points for the failure speed for this commutator at this temperature. Typically 3 to 5 commutators may be tested at each temperature, and the failure speeds for the individual tests are averaged or otherwise adjusted to provide a composite speed/temperature data point.
Additional tests are conducted at a series of higher temperatures, such as 200°F, 300°F, 400°F, 500°F and 600°F, with similar numbers of commutators being tested at each temperature. The composite failure speed/temperature data points provide curves which can be used to rapidly and accurately predict the performance capabilities of the commutator under a wide range of speed and temperature conditions. Two such TDCC™ curves are illustrated in Figure 3. These curves can be prepared for virtually any common commutator, and provide both motor manufacturers and commutator suppliers with a number of significant advantages. Motor manufacturers obtain:
• Heat transfer parameters and calculations;
• Standardized designs;
• Tool savings through use of existing commutator characteristics in motor design; and
• Substantial cost savings by avoiding over-engineering. The commutator supplier obtains:
• Easy, economical and accurate commutator evaluations;
• A valuable tool for evaluating molding compounds, anchoring systems and other aspects of commutator design and engineering;
• A strong base point for future development;
• Product standardization; and
• A superior technical program for commutator marketing and sales.
Those skilled in the art of commutator design and application will readily appreciate other advantages they can obtain through the use of the equipment and techniques described above. They will also appreciate that the specific systems and methods described herein are merely illustrative. Many modifications can be made these systems and methods within the scope of this invention, which is defined by the following claims:
Claims
1. A method for testing, qualifying and/or evaluating the performance capabilities and/or characteristics of commutators, comprising: a. preheating a commutator to a first predetermined temperature, holding the temperature of said commutator substantially constant while rotating commutator at a gradually increasing speed until said commutator fails; b. preheating one or more additional commutators which are substantially equivalent to said first commutator to different predetermined temperatures which are higher than said first predetermined temperature, and holding the temperature of said additional parts substantially constant while rotating said additional commutators at gradually increasing speeds until said additional commutators fail; and c. preparing a graph of the speed at which said commutators failed as a function of temperature.
2. A method according to claim 1 wherein one or more of said commutators are rotated while they are preheated.
3. A method according to claim 1 wherein said first predetermined temperature is approximately 100°F.
4. A method according to claim 3 wherein said different predetermined temperatures comprise approximately 200°F, 300°F, 400°F, 500°F and 600°F.
5. A method according to claim 1 wherein the speed at which one or more of said commutators is rotated or increased at a rate of about 100 to 200 RPM per second.
6. Apparatus for testing, qualifying and/or evaluating the performance capabilities and/or characteristics of commutators, comprising: a. a rotary support for said commutators; b. a heating system adapted to heat said commutators to a predetermined temperature and to maintain the temperature of said commutator substantially constant during a test; c. a variable speed drive to rotate said support at a gradually increasing speed; and d. a sensor adapted to detect structural failures of said commutator; and e. a high speed camera adapted to take a series of pictures of said commutator when said sensor detects a structural failure.
7. Apparatus to claim 6 wherein said camera is capable of taking pictures of said commutator at a rate of at least 8,000 frames per second.
8. Apparatus according to claim 6 further comprising one or more strobe lights adapted to illuminate said commutator while said camera is taking pictures of the commutator.
9. Apparatus according to claim 6 wherein said variable speed drive is adapted to rotate said support at speeds up to about 100,000 RPM.
10. Apparatus according to claim 9 wherein said variable speed drive is adapted to increase the speed of rotation of said support at a substantially constant rate.
11. Apparatus according to claim 10 wherein said substantially constant rate is between about 100 and about 200 RPM/sec.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2001253523A AU2001253523A1 (en) | 2000-04-14 | 2001-04-16 | Method and apparatus for testing commutators |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US54900100A | 2000-04-14 | 2000-04-14 | |
| US09/549,001 | 2000-04-14 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2001079824A1 true WO2001079824A1 (en) | 2001-10-25 |
Family
ID=24191250
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2001/012277 WO2001079824A1 (en) | 2000-04-14 | 2001-04-16 | Method and apparatus for testing commutators |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU2001253523A1 (en) |
| WO (1) | WO2001079824A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109444142A (en) * | 2018-12-26 | 2019-03-08 | 哈工大机器人（岳阳）军民融合研究院 | Ion source circumferential direction spoke vibrates remote measuring system and measurement method |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5567052A (en) * | 1992-08-03 | 1996-10-22 | Matsushita Electric Industrial Co., Ltd. | Temperature distribution measurement apparatus |
| US5810477A (en) * | 1993-04-30 | 1998-09-22 | International Business Machines Corporation | System for identifying surface conditions of a moving medium |
| US5834661A (en) * | 1995-11-15 | 1998-11-10 | Agency Of Industrial Science & Technology, Ministry Of International Trade & Industry | Method of detecting defects in materials using infrared thermography |
| US5864238A (en) * | 1996-07-10 | 1999-01-26 | Matsushita Electric Industrial Co., Ltd. | High speed dynamic run-out testing apparatus and method |
| US5877688A (en) * | 1995-04-12 | 1999-03-02 | Matsushita Electric Industrial Co., Ltd. | Thermal object measuring apparatus |
| US6113262A (en) * | 1999-01-22 | 2000-09-05 | Trw Inc. | Apparatus for testing electrical components |
-
2001
- 2001-04-16 AU AU2001253523A patent/AU2001253523A1/en not_active Abandoned
- 2001-04-16 WO PCT/US2001/012277 patent/WO2001079824A1/en active Application Filing
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5567052A (en) * | 1992-08-03 | 1996-10-22 | Matsushita Electric Industrial Co., Ltd. | Temperature distribution measurement apparatus |
| US5810477A (en) * | 1993-04-30 | 1998-09-22 | International Business Machines Corporation | System for identifying surface conditions of a moving medium |
| US5877688A (en) * | 1995-04-12 | 1999-03-02 | Matsushita Electric Industrial Co., Ltd. | Thermal object measuring apparatus |
| US5834661A (en) * | 1995-11-15 | 1998-11-10 | Agency Of Industrial Science & Technology, Ministry Of International Trade & Industry | Method of detecting defects in materials using infrared thermography |
| US5864238A (en) * | 1996-07-10 | 1999-01-26 | Matsushita Electric Industrial Co., Ltd. | High speed dynamic run-out testing apparatus and method |
| US6113262A (en) * | 1999-01-22 | 2000-09-05 | Trw Inc. | Apparatus for testing electrical components |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109444142A (en) * | 2018-12-26 | 2019-03-08 | 哈工大机器人（岳阳）军民融合研究院 | Ion source circumferential direction spoke vibrates remote measuring system and measurement method |
| CN109444142B (en) * | 2018-12-26 | 2021-05-28 | 哈工大机器人（岳阳）军民融合研究院 | Ion source circumferential spoke oscillation remote measurement system and measurement method |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2001253523A1 (en) | 2001-10-30 |
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