Why is oven baking time such a hot issue?

Time is money...is the short answer.

“In your kitchen, turning up oven temperature will not bake a cake faster, it will just burn the exterior leaving the inside raw. So too, is the effect in commutator construction.”

— Excerpt from Connections Commutator Repair Guide

Do you expect to season your commutator while it is operating? Probably not.

That’s our job. Thorough baking cycles are imperative to stability in operation. Mica v-rings aren’t completely cured until a comm is fully at temperature (350° F) for a minimum of 4 hours.  But, there’s more. Copper and steel expand and contract at different rates and by different amounts.

Full thermal cycling ensures that none of this has to happen when your production is on the line.

We are ICC, and improving commutators is our only job. 
Our industry depends on it.

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If you would like a copy of our technical commutator repair guide, that contains 31 chapters on everything from troubleshooting and diagnosing field issues to frequently asked questions. Please send a request to Info@iccinternational.com.

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Split Ring Manufacturing

ICC manufactures not only commutators but slip rings as well. Below you'll see some of the steps involved to create a new set of bronze slip rings with G-10 insulation. 

Before work can begin on the mill a program is designed by our engineers. After the program is working properly the slip ring is clamped center of the machine and the mill can locate the exact points of machining. 

Split Rings after excess has been machined.

The next step is to drill the holes.

G-10 Insulation

G-10 is also machined in house. 

Final Step is assembly. In this case the steel hub was reusable, so it was sandblasted and painted back to like-new condition. 

When should you buy a complete new commutator?

Most of the time, don't.
A "new" commutator refers to a commutator designed and built from scratch, including all copper, mica and steel components.

The key is steel:
The only time you need a new commutator is when you do not have an existing steel part in good condition to fit the style and size of commutator you need.
• Conversion
• Replacement of damaged parts
• Spare
• Design improvement
Conversion: When an existing unit is molded (i.e. nonrefillable), the commutator needs to be replaced. Either a new molded unit, if available, can be purchased, or a new v-ring or glassband refillable commutator can be manufactured. None of the steel components of molded commutator should be re-used (see Motor Fax Issue 11) due to design limitations and space requirements for maximum stability. Conversions between refillable types also require new steel parts.

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Replacement of Damaged Parts: Whether damaged from arcing in operation, galded or warped from removal from the shaft, or cracked due to porous castings, damaged steel parts must be replaced to ensure stability of the commutator in operation.

Spare: With the aim of reducing down time for the future, manufacturing a spare new unit is another circumstance in which new steel is a requirement. Either purchased from the OEM or designed by an aftermarket manufacturer, key dimensions can be obtained from prints or from the existing unit, ideally upon refill. Alternatively, if shaft profile information is available, along with any flange mount details if required, a new unit can usually be designed. As long as accurate and detailed information about the external dimensions of the commutator and its application environment is available, a new commutator can typically be designed to fit.

Design Improvement: In some cases, an existing steel design may cause problems in a specific application. For example, a v-ring commutator with a floating front cap and no spool may prove unstable or particularly susceptible to contamination in the wrong environment.
New steel can be designed to incorporate a front bore fit and spool to address the operational issues. In short, buying a new commutator when a refill is an option is rarely the most cost effective or timely choice. With no sacrifice in quality by re-using good quality steel parts, refilling a commutator typically represents the best option available in motor repair.

Should you or your customer have any questions regarding this issue, contact an ICC representative and we will be happy to assist you in making a decision on your specific
situation.