Custom commutators in less than 6 weeks
A leading company manufacturer of industrial floor polishers, has involved us to make a special electrical commutator, designed specifically for a new electric motor, which could improve the power ensuring an improvement compared to the compactness. The cost of the mold is a very heavy voice when it’s about projecting a custom commutator. Contacting RD Europe Group, the company has been able to innovate his motor at a much lower cost than what expected because we could adapt a pre-existing mold to the specific requirements of this project. This commutator was a 42 bars, track diameter 46 mm, length 30 mm and bore 18 mm. The motor features: class H, 13,000 RPM, isolation 2000 V bar / bush. For this it’s necessary to contact a company specialized in electrical collectors such as RD Europe, a guarantee of reliability and professionalism also in view of the savings. In 2017 the new commutator will be assembled onto a new line of DC motors for industrial polishers, with an estimated potential of 1,500 machines in the launch phase.
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ELECTRIC COMMUTATOR: FROM DESIGN TO REALIZATION IN ONLY 6 WEEKS
A major Italian company trusted on the reliability of RD Group Europe to overcome a problem of electric commutators availability. The existing provider was no longer able to guarantee an electrical commutator for the machine. It was a 24 bars commutator with a crown diameter of 41 mm and 37.5 mm brush track diameter, bore 15 mm and a length 24 mm for only 3500 pieces. It was not obvious to find someone who could quickly meet the demand for a dedicated collector, with similar amounts and timing under three months. Thanks to the versatility and experience of RD Europe we were able to put produce and delivery these parts within six weeks, letting the customer not losing sales.
Impossible spare parts?
Call us to know how much values the quality for your company.
Too much electricity to commutator? The RD Europe’s solution for hydraulic pump
A company manufacturer of motors for industrial forklift hydraulic pumps has recently contacted RD Europe Group to realize a commutator that could solve different existing problem on the vehicle. First of all, battery brought too much electricity to commutator, particularly in case of overload. This means a high stress level for commutator that is subject to wear, and a special maintenance is necessary. Secondly the commutator is subject to thermal stress that wears brushes too. Finally was necessary the improvement of isolation class in H. RD Europe team has worked to find out a solution to improve commutator endurance. Starting from material: we have realized the new commutator in copper, with a percentage of silver 0.08 % comparing with standard 0.03 % Ag. We increased thickness of myca, improving isolation class. To solve the problem of deformation we have worked on phenolic resin and fiber glass rings support, keeping together the 29 commutator’s bars, making support lines to reduce deformation. In this way we have improved rotor fluidity. The commutator works with more continuity also in case of electricity stress, granting a better electric pump performance. RD Europe Group listens your needs and realizes evolved commutators for your products.
Hook commutator RD Europe Group: the case history
In collaboration with one of the largest manufacturers of DC motors in Europe, we have realized a hook commutator to improve the power of an electric motor for industrial washer-dryer. The target was to create a hook commutator to speed up the production process by replacing the traditional commutator used in the previous models of the machine. Thanks to the passage to a hook commutator, the client optimized semi-automatic lines winding by an important time (and cost) saving.
Secondly, thanks to the RD Europe commutator, the customer could improve the life of the brushes ensuring a better absorption of current to the motor, even on larger workloads. The commutator Rd Europe has also improved bar/bar insulation, uses a certified UL resin, 0.08% silver copper alloy, and ensures a thermal class H 180 ° C. The commutator realized by RD Europe responds perfectly to the needs of the client and consists of 32 bars, a brush diameter of 43, 5 mm, insulation thickness of 0.65 +/- 0.05. The collector has exceeded the speed test at 18,000 rpm at a temperature of 140 ° C. Another innovation branded RD Europe.
Contact us to improve your products thanks to the design of customized commutators for your needs!
Special Commutator for home appliances: the industrial orange juicer case
A Swiss company producer of food services machinery has contacted RD Europe Group to improve performances of industrial orange juicer. The machine, a high level orange juicer, used by big chains of catering, did not reach the manufacturers requested standard. The reason? A commutator not fully suitable. RD Europe Group has studied the old commutator and projected a special model, in order to grant a better performance of electric motor. First of all improving electric rotor endurance thanks to a higher thickness of copper on commutator’s bars. Secondly improving material: RD Europe realized the new commutator with a silver-plated copper 0,03% ensuring a better electric commutation and also a longer endurance of brushes. The commutator has overpassed all tests to work at requested features: 37.000 rpm with an inferior bar movement of 0,003 mm. The final commutator is has 24 hooks, a diameter of 28 mm, length 19 mm and a hole of 10 mm. RD Europe Group projects and realizes special commutators. Do you want improve your motor performances? Discover how to innovate, saving money, thanks to RD Europe Group.
Huge electric commutators up to 1000 mm, for ambitious projects
In some areas it is essential to predict with great accuracy the maintenance of complex systems. Or act with the utmost speed in case of failures. It's the case of steel plants which need continuous illumination: in this case the speed of supply of spare parts is fundamental to ensure quick maintenance. These pieces are often very expensive and complex, difficult to find rapidly. A large Italian steel company has contacted us for a commutator with large bars to keep in stock in case of failures. The commutator must have specific dimensions of 757 mm crown diameter, brush track length 474 mm and 210 bars. RD Europe produced this commutator ensuring a single piece in just 60 days as per customer's request. RD Europe can project from the beginning or produce on existing drawing commutators up to 1000 mm diameter for large motors.
The special commutator for Ski-lift motor
In cooperation with a manufacturer of electric ski-lifts, RD Europe Group designed a special commutator responding to power demands, safety and the specific engine costs. Our team has studied the needs then designed a commutator ad hoc for a very big and very powerful motor. In addition to specific measures, the commutator had to assure a shaft axis height of 180 mm, 195 bars, a crown of 250 mm and a brush length of 85 mm. In a few days our team has solved all the needs, starting the production of a very large commutator to fit the engine of the ski lift, a 2650 rpm system, 1000 Nm of torque with a power consumption of 15000 W. Rd Europe Group designs and manufactures commutators for every need, from miniaturized collectors to those for heavy industry up to 1000 mm in diameter. Contact us for more information about our service!
The commutator axial contact for gearbox for electric scooter, Made in Italy
In collaboration with an Italian company, leader in the world, also producing electric scooters for elderly and disabled, RD Europe Group has designed a commutator for compact gearbox, efficient and lightweight ... entirely Made in Italy. Customer's request was particularly interesting: the need was in fact to re-design and build a commutator 16 hooks as flat as possible to reduce clutter and adapt to the engine on which is assembled. RD Europe Group has so designed a special commutator in which the brushes are working in parallel respect to the drive shaft (and not perpendicularly as in conventional commutators). In this way, in addition to being more compact, the commutator provides a greater bearing surface to the brushes, which work more efficiently in a small space. The item made by RD Europe has a diameter of 40 mm and a total length of 20 mm. The piece will be inserted in approximately 50,000 engines for scooters for disabled.
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Replacement close-out sale: the support of RD Europe for the after-sales service
A Power Tools company involved us to produce 50,000 pieces of a commutator for an engine now out of the business which had to assure after sales service. A big problem for many companies that fail to ensure the required volumes of spare parts. In this case, customer’s request was to have 50,000 commutators 24 bars, diameter 30/28 mm with 11 mm bore and 8 brass bushes. A request not particularly complicated for RD Europe, but none of the suppliers end customer had addressed earlier had managed to supply. The commutator had to overpass complex tests (46,000 rpm at 160 degrees for 1 minute with less swing than or equal to 0.015 mm) it was produced, tested and delivered in few weeks.
Spare parts? Ask to RD Europe, the cheapest and fastest solution.
Commutator for hair-drier: The revolution made in Italy
To became independent of the market and improve its main product, an Italian company manufacturer of professional hair-driers met us to re-project, together with their R&D dept., the internal electric commutator. The new commutator must grant a longer brush last (2200 hours of usage), a motor power of 2150 WATT and an air capacity of 80 meters cube/hour, respecting European regulation and American UL/CSA. RD Europe Group so projected a new and solider commutator (with a brass bush instead of resin) and increasing thickness of isolation mica (form 0.3 to 0.5 mm). Commutator, moreover, must respect precise dimensions to be conform to the existing hair-drier model. After some weeks of tests, RD Europe group created an “ad Hoc” solution for customer, brilliantly overpassed commutator’s spin test (50.000 rpm at 150 C° of temperature for 2 minutes with a radial movement <= 0.01 mm). Today, RD Europe has produced half million of pieces. Italy is biggest hair-drier producer in the world with over 4 million of pieces per year. On half million is assembled a RD Europe commutator.
Ensure spare parts, also at the end of the production: Automotive case history
The world leader in the automotive sector has involved us to help him solve a thorny problem: to ensure spare parts for an electric motor out of production, but with the need to ensure 300,000 pieces per year of spare parts for at least 3 years. In detail, it was needed availability of a large number of special commutators for the ABS engine of a Spanish car manufacturer. It is a special commutator to be made without a drawing! We then studied the piece for the motor: a small hook commutator of difficult realization: 10 hooks, a diameter of only 15 mm with a bore of 5 mm and a length of 16 mm. Our customer, a well known multinational company, did not find any supplier meeting his needs ... except RD Europe Group!
If you have an "impossible" request, call RD Europe: we are ready for any challenge!
THE PERFECT COMMUTATOR IS THE ONE MADE AD HOC
RD EUROPE Group designs and realizes electrical commutators ad hoc studying customer needs and investing in research and development. The last project carried out regards the requests for a client who needed a new commutator, able to withstand over 180 °C with an insulation class H and able to pass the electric type approval test with 1000 V bar/bar and 2.500 V bar/bush, required by UL American standards. RD EUROPE Group team then redesigned the commutator specifically to respond to customer’s specific needs without converting the production nor re-setting of the motor design. Goal achieved! Contact us to improve, together with RD EUROPE team, your product.
The hook commutator automatically assembled
An hook for electric traction motor can do the difference. RD Europe has projected for a leader customer, in automation field, an innovative solution to optimize production costs for electric traction motor.
We studied the “starting” commutator, that is a barrel commutator which respond to all motor requirements, but it needed a very complex assembly, saw that was semiautomatic, and high costs.
RD EUROPE’s R&D has created a new hook commutator that can substitute the previous, permitting automatic wrapping.
Today, thanks to this innovation, all the motor could be produced at industrial level, becoming suitable for customer production’s line.
The commutator has been realized following American market's standard, and it is UL/CSA certificated.
Are you interested in? Contact us!
Commutator: smaller is better
In collaboration with the development department of a manufacturer of coffee machines, RD Europe it has studied a collector of very small dimensions with 8 hooks and shaft bores of 4 and 6 cm which guarantees a perfect switch with brushes without sacrificing speed and efficiency. The RD Europe commutator guarantees over 2,000 hours of maintenance-free functioning of the brushes, a feature that ensures a much longer service intervals than the average. The development of the RD Europe commutator allowed the customer to produce smaller machines without compromising on quality and efficiency.
Do you need a customized commutator? Contact us for a project.
The commutator UL/CSA for power tool motor
RD Europe Group, in partnership with a manufacturer of grinders, has developed a commutator fitted with a special copper hook to improve the performance of power tool motors, ensuring an insulation class comply with UL/CSA standards.
The special copper hook is designed to wrap the copper wire of larger cross-section up to 1.25 mm, and to improve the welding of the hook on automatic lines. Even the resin class H has been designed to comply with UL/CSA standards of the American market, much more restrictive than European standards: the insulation bar/bar is obtained thanks to a special mica produced by SUMITOMO Japan.
D you need a specific component for your engine? Learn how to design it together with RD Europe Group.