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The Commutator Connection - (5 MB) provides a detailed description of the Commutator Fusing process and the Commutator Brazing process in the English language. 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.

Chinese Translation of The Commutator Connection - (2.1 MB) This is a translation of the above paper in Chinese. The graphics from the original English language paper were not displayed in the same high resolution. We suggest that you download both the English and Chinese language versions, so that you can get a better idea of what the graphics describe.

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 Allem.

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.

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.

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.

Commutator Slotting, Slitting and Undercutting is a technical paper that describes the cutting of predominately copper that is used in universal or DC electric motor's commutator. This paper describes three completely different operations that can be performed to a commutator.

Magnet Wire Bonding is a technical paper that describes the process of attaching or gluing adhesive overcoated magnet wire, in the form of a wound coil, to adjacent magnet wires of the coil, through the use of very fast heating. The film insulated magnet wire, wound in a coil, armature, stator, etc., has a film overcoat of heat activated adhesive, which when heated becomes active. This process can eliminate taping, resin impregnation, lacing, gluing, etc.

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