FIELD OF THE INVENTION

[001] The present invention generally relates to a starter apparatus for a motor vehicle, and more particularly relates to new arrangement of an armature coil, to avoid separator projection and to improve the manufacturing cycle time.
BACKGROUND OF THE INVENTION

[002] The starter armature assembly is the electrical heart and mechanical backbone of the starter motor. It is the largest and heaviest component in the starter motor. The armature assembly converts electrical energy into mechanical energy. It produces just as much work, if not more, as the other parts of the starter. In most cases, when the armature assembly fails, the starter motor will need to be replaced, because, due to the efficiency of mass production.

[003] The armature assembly consists of a round shaft, a metal framework or armature, electrical wiring loops or armature winding, and commutator bars. The armature shaft is supported at the ends by the starter bushings or bearings. The metal framework or armature is cylindrical shaped with a hole bored through the center to accommodate the armature shaft. The armature is either press fit unto the shaft or keyed to the shaft to prevent spinning on the shaft. The armature has several slots along the length and around the outer circumference. The slots accommodate the electrical wiring loops or armature windings. The number of slots is determined by the number of armature windings. For example, if there were ten armature windings then there would be twenty slots. Each slot holds one half or one leg of each armature winding. The armature windings are heavy gage, enamelled single strand copper wires, similar to house wiring. These windings are tightly wound into the armature slots to prevent damage while at the same time protected from contacting the armature preventing electrical shorts. The ends of the windings extend slightly beyond the back end of the armature in relation to the starter. The ends of the windings are attached to a commutator which is secured to the shaft in back of the armature. The commutator is a set of copper contact bars shaped like a cylinder but not as long or as large in diameter as the armature. The smaller diameter is necessary to accommodate the brushes. The bars are separated or insulated with flexible plate which keeps the bars from electrically shorting together. The number of bars are determined by the number of wire ends. For example, if there were ten armature windings then there would be twenty bars because each winding has two ends. The commutator acts as an electrical switch reversing the flow of energy in the armature windings.

[004] A conventional armature arrangement for a starter motor is provided in Fig. 1, which illustrates a commutator (1) connects the entire armature assembly through armature shaft (6). In commutator the armature coils (2) are inserted by means of sequential arrangement which is covered through a band (5), this hairpin arrangement which connects the whole assembly through the steel laminated core assembly (4). The entire set up in turns known as armature assembly which is an important component in the starter motor.

[005] The arrangement of the armature coil plays a vital role in the armature assembly, Fig. 3 shows the conventional method of aligning the armature coil (3) in the coil slot (1) present in the commutator. In this method of the arrangement, when the pressure is applied through the electrode the separator (2) starts too pushed out and the entire set up is collapsed. More over the armature coil shape also turns from the circle to spherical shape. By this type of arrangement, the utility of current density taken by electrode is high and also load applied to the electrode to press the armature coils into the slots also more. By the above mentioned discrepancies the time taken for the cycle period also increases drastically.

[006] Fig. 4 deformation the misshaping of entire commutator assembly and the separator while the pressure applied through electrodes. By this conventional method the usage of current density and cycle time of producing armature assembly gone to its peak.
OBJECTS OF THE INVENTION
[007] The present invention overcomes the shortcomings associated with the background art and achieves other advantages not realized by the background art.

[008] The principal object of the present invention is to provide a new arrangement of armature coil which seated in the coil slot without disturbing the commutator shape and the separators.

[009] Another object of the present invention is to design the armature assembly that is simply adaptable with the existing starter design without much modification therein.

[010] Yet another object of the present invention is to configure the flattened armature coil for the coil slot in the commutator without affecting performance of any of the components.
SUMMARY OF THE INVENTION
[Oil] To solve the above-described problems, the present invention has been devised. It is an object of the present invention to provide an effective armature coil arrangement for starter motor.

[012] The present invention is to provide a flattened armature coil which seats in the coil slot of the commutator without any sort of high load applied on it and by this the cycle time of producing armature assembly reduced to some extent. Moreover there is no disturbance to the separator which is present in the commutator assembly, and the shape of the armature assembly remains the same even after the insertion of the armature coils. Consumption of current density taken by the electrode required to press the armature coil in the slot also reduced to the maximum level. The temperature peak and the copper softness happens at time of pressing also reduced to an extent.

BRIEF DESCRIPTION OF THE DRAWINGS:

[013] The present invention will be better understood fully from the detailed description that is given herein below with reference to the accompanying drawings of the preferred embodiments of the present invention, which, however, should not be deemed to be a limitation to the invention to the specific embodiments, but, are for the purpose of explanation and understanding only.
In the drawings:

[014] Fig. 1 is a cut section of armature assembly of a starter motor.

[015] Fig. 2 is a commutator section in an armature assembly of a starter motor.

[016] Fig. 3 is about conventional method of arranging armature coil in commutator.

[017] Fig. 4 is about pressure applied on the armature coil through electrode and its
effect.

[018] Fig. 5 is a new arrangement of armature coil in the coil slot.

[019] Fig. 6 is a flattened armature coil arrangement in the coil slot and its effect
while the pressure applied through the electrode.

DETAILED DESCRIPTION OF THE INVENTION

[020] While this invention is susceptible of embodiments in many different forms, the detailed description of the preferred embodiments with reference to the corresponding drawings shown herein below are to be understood that the present disclosure shall be deemed as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of FIG 1 - 6.

[021] Referring to Fig. 1, the commutator (1) with the armature coils (2) arranged alongside with the separator (3) of the armature assembly. The armature shaft (6) is connected in the center of the armature assembly which interconnected the entire set up. The core assembly (4) covers the entire setup through the steel lamination and the band (5) tightly engaged the commutator and the armature coils. The entire set up of the armature assembly plays a vital role in the starter.

[022] In the armature assembly, commutator plays a vital role, the armature coils is made from copper placed in the proper location to enhances electrical efficiencies due to its higher electrical conductivity. In the Fig. 2 the commutator section illustrates the coil slot (1) where the armature coils to be seated sequentially for electric conductivity. And the separator (2) acts as an insulating material which protect the electric flow from one to other coil slot. The clear space provided for arranging armature coil one on another to provide the current conductivity.

[023] The armature coil winded on the core assembly to end to end and the leads are inserted in the commutator and this windings were covered through the steel lamination. And the band rotated on the armature coils by which the position shouldn't be changed after the pressure applied through the electrode.

[024] Referring Fig. 3, an conventional arrangement of armature coils (3) seated in the coil slots (1), once the pressure applied through the electrode the armature coils starts shrinking and the shape of the coil converts as spherical from circle, which in turn disturb the separators (2) located in between the coil slot for insulation purpose.

[025] Fig. 4 provides a clear picturization of the armature coil arrangement wherein once the pressure applied on the armature coil through the electrode (1), this action needs more load and high current. Through this action the cycle time of producing the armature assembly also increases mutually. Once the pressure exceeds the separators (2) starts pulling out from its position and projecting outside of the commutator. Therefore the entire shape and arrangement of the commutator collapses and the operation also off tracked from the original one. The armature coils (3) seated inside the coil slots tends to change its shape from circular to spherical or oval shaped. This misshaping makes the entire commutator shapeless as well as it affects the functionality of the armature assembly.

[026] The new arrangement of armature coils (1) is displayed in Fig. 5, wherein the slight cut is made in the armature coils by which it seated properly in the coil slot. This cut at armature coil makes its seating arrangement as perfect without disturbing any part of the commutator. By this the separator (2) also arranged to its original position and acts a perfect insulating material, the cut section of armature coils are aligned in the single line when pressure applied through the electrode and its operation takes places as per the arrangement.

[027] Referring to Fig. 6, when the pressure is applied to electrode (1), on the armature coils (3) with the slight cuts both the coils placed one on the above perfectly and the connecting point of the armature coil falls on the straight line in between these coils. The separator (2) which acts as an insulating materials not disturbed by any means, the positioning plays a major role in the armature coil arrangement. Through this arrangement the current density taken by the electrode will be come down and the load applied on the electrode also comes down drastically.

[028] In another embodiment, by this arrangement production time or cycle time taken to produce the armature assembly also comes down without affecting the shape. And the major advantage of this arrangement is to maintain the separator in its original position without any sort of disturbance.

[029] In yet another embodiment, the void filling area which projected in Fig. 6, commutator material perfectly filled by electrode force. By which the commutator assembly in the armature were perfectly aligned to its original position, the space where the armature coils aligned one on the other known as void filling area. This filling area were packed through the commutator material at time of pressure applied through the electrode.

[030] This method of manufacturing an armature assembly numerous advantages in comparison with conventional methods of manufacturing. These include a reduced the load, reduced consumption of material, reduced energy consumption, the possibility of producing high volume of armature assembly by increasing the cycle time. Hence, the preferred embodiment disclosed in the foregoing description should not construed as a limitation to the scope of the present invention.

[031] It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Accordingly, the preferred embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention, which is to be given the full extent of the appended claims.

CLAIMS

We claim:

1) Armature coil arrangement for starter motor comprises of a flattened armature coils for the coil slot in the commutator section without affecting performance and shape of any of the components in the armature assembly.

2) An arrangement as claimed in claim 1:
wherein said armature coil which seated in the coil slot without disturbing the commutator shape and the separators in the armature assembly.

3) An arrangement as claimed in claim 1:
wherein said armature coil is made up of copper material, because of its high conductivity, less molecular weight and high ductility properties.