Mass produced for small to mid-sized DC motors, disposable moulded commutators offer the end user low performance and low reliability. As well, it can be difficult for our winding customers to source a molded/riveted replacement for the commutator they need. In these circumstances EMCC/Thistle Industries can re-engineer and convert these commutators to high performance, high reliability v-ring style commutators. Steel v-ring style cores allow for easy commutator re-fill and repair.
High Grade Copper & Steel Cores
Moulded commutators are often produced cheaply for OEM's using lessor quality copper (alloy 114,105,107) and construction materials. Copper bars are punched - not machined, offering lower precision assemblies. Bakelite, cast iron and phenolic compound cores often lead to bar movement and reduced commutator stability. Moulded type commutators are not repairable, so when they fail, they must be replaced or re-engineered into a complete new v-ring style commutator . Our moulded conversion commutators are only built with alloy 116 (high silver content copper) that offers better wear and conductivity.
At EMCC these types of commutators are re-engineered with high grade steel v-ring style cores bound under pressure that can be re-used over and over. Steel cores allow for increased bar stability, better brush wear and longer life cycle of the entire motor. It also allows for minor repairs should the commutator fail in the future without scraping the whole commutator.
Most moulded commutators run into issues of electrical arching between copper bar segments and from the bars to the core. They often do not have mica extensions between the bar segments at the riser end of the commutator. This allows for dust build up and arching. The same is true for the end, opposite the rise. Flush mounted cores with limited or reduced insulation extensions allow for build up and eventual grounding out.
Our Re-engineered v-ring style commutators have individually machined copper bars with tolerances of less than .001 thousand of and inch from end to end. Each copper segment is insulated with high quality mica that extends past the riser end of the commutator. Steel cores are well insulated by mica v-rings that extend past the brush end of the commutator - providing superior resistance to electrical arching.
Many moulded commutators have small diameters and low bar counts. We are capable of re-engineering and manufacturing moulded and riveted (Nippert style) commutators as small as 3" in diameter. The larger the diameter, the easier they are for us to re-engineer. Riser widths, bar lengths, dust grooves, bore sizes, keyways, venting and slot sizes can be customized to suit your needs.
24/7 Emergency Repairs
When failures occur, EMCC has the manpower and ability to work around the clock to get you the commutators and coils you need. With our 24/7 production capability, we deliver unmatched commutator and coil quality with turn around times that are the best in the industry. This means your coil order can be on its way in 24 hours and your commutators in 24-48 hours.