0 British Standards Institution.

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COPYRIGHT British Standards Institute on ERC Specs and Standards
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B S I BS*bl l ' J y 85 81 l b 24b I a9 0072694 3 I
BS 1434 : 1985
Foreword
This British Standard, which has been prepared under the
direction of the Non-ferrous Metals Standards Committee,
supersedes BS 1434 : 1970 which is withdrawn.
This standard is a full technical revision of the 1970 edition
and takes into account the corresponding requirements of
IEC 356 : 1971 'Dimensions for commutators and slip-rings'
published by the International Electrotechnical Commission
(IEC). The principal objectives in preparing the revised
edition were as follows:
(a) to extend the size and shape ranges covered in
accordance with demand for copper section for uses
ranging from mass produced commutators through to
special purpose applications (where present limits appear
to have satisfied demand, no changes have been made);
(b) to provide adequate choice within practical limits so
that cost/accuracy and size demands can be optimized;
(c) to take, in each area of the specification, the best
elements from both BS 1434 : 1970 and IEC 356 : 1971
and combine them to give an improved and more
practical standard;
(d) to simplify presentation and eliminate redundant
text while retaining the practical essentials.
Useful information has been included in appendix A which
lists the preferred nominal heights (see A.l) for commutator
sections supplied as bar or coil, and the preferred nominal
diameters (see A.2) for finished commutators, in which
material complying with this standard i s supplied.
Compliance with a British Standard does not of itself
confer immunity from legal obligations.
COPYRIGHT British Standards Institute on ERC Specs and Standards
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BS 1434 : 1985
Contents
Foreword
Committees responsible
Page
Inside front cover
Back cover
Specification
Scope 2
Definitions 2
Information to be supplied by the purchaser
General 2
Material 2
Tolerances on dimensions and shape
Sampling 9
Determination of hardness 9
2
2
Appendix
A Preferred nominal sizes
Tables
1
2
3
4
5
6
7
8
9
10
11
12
13
Chemical compositions and minimum hardness
Permitted proportions of bars of different
actual lengths in any one delivery of mill lengths
Tolerances on length for specified lengths
Tolerances on length for blanks and segments
Tolerances on height
Thickness measurement positions for commu-
tator bar segments or blanks
Tolerances on thickness
Tolerances on specified angle
Tolerances on shape error and shape constants
for the shape of the side faces
Maximum deviation from straightness of bar
Maximum twist for bars, blanks and segments
Preferred heights, H, in mm, of sections for
commutator bars
Preferred nominal diameters, in rnm, of
finished commutators
Figures
10
2
3
3
3
4
4
7
7
7
8
8
10
10
Segments 3
positions for thickness, angle and shape
Qeviation from specified angle 7
Tolerance on shape of the convex thick edge
Tolerance band for the shape of the thin edge
(referee method) 9
Main dimensions of cross sections of commu-
tator bar segments or blanks and measuring
5
9
9
Measuring area for Vickers hardness
1
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BSI B Sr L Y3 4 85 m Lb2Ybb9 O072696 7 m
BS 1434 : 1985
Specif ication
1 Scope
This British Standard specifies requirements for flat sided
wedge-shaped copper sections in bars (straight lengths and
coils), blanks and segments, suitable for the manufacture of
commutators for rotating machines, in the following size
ranges:
(a) thick edge thickness ( T) up to 15 mm;
(b) height ( H) from 6 mm to 200 mm;
(cl height to thin edge ratio ( Hl r ) up to 50.
This standard does not cover copper for flat face
commutators, commonly rectangular section strip and bar,
which is covered by BS 1432 and BS 1433.
NOTE. The titles of the publications referred to in this standard
are listed on the inside back cover.
(f) the thickness dimensions ri and r 3, or t and T
(see 6.4, table 6 and figure 2) and the tolerance class
(see 6.4 and table 7);
(9) the angle, (Y (see 6.5, table 8 and figure 3);
(h) the shape (flat or convex) of the thick edge (see 6.9
and figure 4).
3.3 Commutator segments
The following information shall be provided:
(a) the information detailed in items (a) to (h) of 3.2;
(b) the length of the commutator segment, L u
(see 6.1.3, table 4 and figure 1);
(c) the height of the commutator segment, Hu , and the
tolerance class (see 6.3, table 5 and figure 1);
(d) a drawing of the shaped segment required, especially
if the blank i s other than L-shaped.
2 Definitions
4 General
For the purposes of this British Standard the following
definitions apply.
2.1 commutator section. A solid, flat sided product of
wedge-shaped cross section, with or without a stepped
section (see figure 21.
2,2 commutator bar. Commutator section, intended for
use in the manufacture of commutator blanks or segments,
usually supplied in mill, multiple or specified lengths.
NOTE. Commutator bar in the smaller section sizes may be supplied
in coils.
2,3 commutator blank. A short length, cut or fabricated
from a commutator bar, that is of plain shape,
2.4 commutator segment. A short length, cut or fabricated
from a commutator bar, that is shaped.
3 Information to be supplied by
the purchaser
3.1 General
The information given in 3.2 and 3.3 shall be supplied by
the purchaser in the enquiry and order to assist the
manufacturer in supplying the correct material.
3.2 Commutator bars and blanks
The following information shall be provided:
(a) the quantity required;
(b) the material grade (see table 1);
(c) the length and whether this is to be supplied in mill
lengths (see 6.1.1 and table 21, specified or multiple
lengths (see 6,1.2 and table 31, blanks and segments
(see 6.1.3, table 4 and 3.3);
(d) for the smaller sections, supplied in coil, the coil size
and/or mass;
(e) the height ( H) and tolerance class (see 6.3, table 5
and figure 2);
Copper commutator bars (straight lengths and coils), blanks
and segment shall comply with the material requirements
specified in clause 5 and the tolerances on dimensions and
shape specified in clause 6.
Methods for sampling and the determination of hardness
shall be as specified in clauses 7 and 8 respectively.
5 Material
The chemical composition and the hardness, determined
either by the Vickers or the Brinell methods in accordance
with clause 8, shall be as given in table 1.
Table 1. Chemical compositions and minimum hardness
Material grade
(see item (b)
of 3.2)
1
2
Chemical
composition
CU-ETP-2
(C101/2) of
Cu-Ag-3 of
or CU-FRHC
BS 6017
BS 601 7
Mi ni mum hardness
85 I 80
6 Tolerances on dimensions and shape
6.1 Length
6.1.1 Milllengrhs, The proportions of bars of different
actual lengths that are permitted in any one delivery shall
be as given in table 2 (see item (c) of 3.2).
2
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BSI BS*l1434 85 W Lb24bb 0072b 7 9
Actual bar
length
> <
m m
- 1
1 2
2 4
4 -
BS 1434 : 1985
46
Nil
40 max.
60 min.
Nil
Table 2. Permitted proportions of
bars of different actual lengths in
any one delivery of mill lengths
(see item (c) of 3.2)
Length,
L or Lu
> 6
mm mm
- 100
100 200
200 500
Permifted proportions
Tolerance
mm
f0.3
f0.5
f 1.0
6.1.2 Specified or multiple lengths. The tolerances on
specified length shall be as given in table 3 (see item (cl
of 3.2).
Table 3. Tolerances on length for
specified lengths (see item (c) of 3.2)
(Cl
X denotes corners for measurement of twist.
Figure 1. Segments (see items (b) and (c) of 3.3)
3
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BS 1434 : 1985
6.2 End squareness for blanks and segments
The ends of blanks and segments shall be cut square to the
edges within 0,006 mm per 1 mm of the height dimensions
H or Hu shown in figure 2.
6.3 Height
The tolerances on the height dimensions Hand Hu shown
in figures 1 and 2 shall be as given in table 5 (see item (e)
of 3.2 and item (c) of 3.3).
Table 5. Tolerances on height (see item (e) of 3.2
and item (c) of 3.3)
Height, H or Hu Tolerance
Normal Close
> <
H Hu
H H U
mm mm mm mm mm mm
- 80
f0,4 f0.4 f0.12f0.3
80 125 f0.8 10.8 f0.2 f0.3
1.25 200 f 1.2 f1.2 f0,3* f0.3
* Not normally avajlable for sections where the thickness t
(see figure 2) at the thin edge is less than 3 mm.
6.4 Thickness
The thickness ti and t 3, measured at the positions h and
h 3, as shown in figure 2 and table 6, shall be within the
tolerances given in table 7 (see item (f) of 3.2).
The thickness, t 4, measured at theh4 position as shown in
figure 2, shall be within the following tolerances:
plus tolerance as given for tl and t3 in table 7
minus tolerance 0.10 mm in all cases
6.5 Angle
The deviation from the specified angle shall be determined
from the thickness measurements ti and t3 (see figure 2 and
table 6) by calculating the algebraic difference between the
errors in the thicknesses, A t3 and tl (.e. the differences
between the nominal and the observed values), as shown'in
figure 3. The deviation shall not exceed the negative
tolerances given in table 8 (see item (9) of 3.21,
NOTE. Products may be supplied with a positive angle tolerance by
agreement between manufacturer and purchaser at the time of
enquiry and order.
Table 6. Thickness measurement positions for
commutator bar segments or blanks (see also figure 2)
HU
mm
<10
10
11.2
12.5
14
16
18
20
22.4
25
28
31.5
35.5
40
45
50
56
63
71
80
90
1 O0
112
125
>I35
h'
mm
Hu)*
3
3
3
3
3
3
3
3
3
3
3
3
6 '
6
6
6
6
6
6
6
6
6
6
6
h,
mm
(1/2 Hu)*
5
6
6
7
8
9
10
1 1
12
14
16
18
20
22
25
28
31
36
40
45
50
56
63
( l i 2 Hu)*
mm
Hu)*
7
9
9
1 1
13
15
17
19
21
25
29
33
34
38
44
50
58
66
74
84
94
106
1 20
(Hu - 6)"
h,
IH - h,
for all sizes)
Values rounded to the nearest whole millimetre.
NOTE 1. For heights that are intermediate between successive
values in the above table, thickness measurement positions
corresponcing to the next lower value of Hu .are used.
NOTE 2. If the lower reference plane is used for the rneasure-
ment of stepped sections, the thickness measurement positions
for t , , t 2 and t , are ho (nominal) +h, and ho (nominal) +
h, respectively.
4
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BS 1434 : 1985
1
T
(a) Commutator bar and blanks
T
(b) Commutator blanks to be shaped, or segments
4
A
7 . E X
Ref erence pl ane
L - J
Al t ernat i ve ref erence pl ane
(c) Stepped commutator bar
Figure 2. Main dimensions of cross sections of commutator bar, segments or blanks and measuring
positions for thickness, angle and shape (see also items (e) and (f) of 3.2 and table 6)
5
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Height, H Angle, pl
>
mm
6
20
40
80
140
Q >
mm degree
20 3.6
1.8
40 3.6
1.8
-
80 3.6
1.8
I -
140 I 3.6
I
I -
Tabl e 8. Tolerances on specified angle (see item (9) of 3.2)
Height, H
or Hu
>
mm
6
20
40
80
140
6
mm
20
40
80
140
200
Angle, 01
degree degree
3.6 -
3.6
-
3.6 -
1.8 3.6
- 1.8
3.6 -
1.8 3.6
- 1.8
3.6 -
1.8 3.6
- 1.8
1.8 3.6
- 1.8
Negat i ve tolerance on
specified angle, A t , - A t ,
Normal I Close I Ex:
mm mm mm
0.032
0.020 -
0.025
0.016 -
0.050 0.032 0.020
0.040 0.025 0.020
0.032 0.020 0.020
0.050 0.032 0.025
0.040 0.025 0.020
0.032 0.020 0.020
0.063 0.040 0.025
0.050 0.032 0.020
0.040 0.025 0.020
- 1
0.050 I 0.040
- 0.040
0.032
6
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B S I BS *3434 85 L b24bb9 ~~~ 0072703 7 M
4 1 Angle error
I I
I
Top limit
on. thickness
Lower Mi t
on thickness
r
Figure 3. Deviation from specified angle
(see item (9) of 3.2)
BS 1434 : 1985
6.6 Shape of side faces
The shape of the side faces, Le. the convexity or concavity
and flatness over height, shall be determined from the
thickness measurements ti , t2 and t3 (see figure 2 and
table 6) by calculating a shape error, A f , given by:
where A t i , A tz and A t 3 are the differences between the
nominal and observed thicknesses, undersize values being
negative and oversize values being positive.
The shape error, A f , shall not exceed the tolerances given
in table 9.
In addition, any gap at position hz (see figure 2 and table 6)
between a straight edge spanning the positions hl to h3 and
the actual side face shall not exceed the value, in mm,
given by:
A f
2
x - -
where x, the shape constant, is given in table 9.
Table 9. Tolerance on shape error and shape constants
for the shape of the side faces
Height, Angle, CY
H or Hu
mm mm degree
6 20 3.6
-
'
20 I 40 I 3.6
1
-
I
Tolerance
on shape
error, A f
degree mm
- f 0.025
3.6 -r 0.020
- f 0.032
3.6 f 0.020
- 50.032
3.6 +- 0.020
- f 0.040
3.6 f 0.025
- Lt: 0.050
3.6 f 0.040
Shape
constant, x
mm
0.025
0.040
0.050
0.063
0.080
7
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B S I BS*h434 85 hb24bb 0072702 9 H
BS 1434 : 1985
6.7 Straightness of bar
The maximum deviation from straightness, measured
between two points separated by the distances given in
table 10 along a central longitudinal line on the edges and
faces, shall not exceed the values given in table 10.
6.8 Twist
The maximum twist, .e. the maximum deviation of one
corner of either side face from a plane passing through the
three other corners of that side face, shall not exceed the
values given in table 11 for bars and segments.
Table 10. Maximum deviation from straightness of bar
Bar length, 1
I
mm mm
- 1 O0
100 500
500 -
Maximum deviation f rom straightness.
Measurement distances
2000 mm
mm
-
0.8
6.9 Shape of convex thick edge
The shape of the convex thick edge shall comply with the
following (see item (h) of 3.2):
(a) the highest point shall be within f 0.2T of the line
of symmetry, as shown in figure 4;
(b) the radius of curvature of the highest point, r, shall
not exceed 2 mm or 0.5T, whichever is the smaller;
(cl the total contour of the thick edge, including the
highest point shall be within the 1 mm tolerance band
shown in figure 4.
6.10 Shape of the thin edge
The total contour of the thin edge shall be within the
tolerance band of 1 mm or 0.5t , whichever is the smaller,
shown in figure 5.
1 Table 11, Maximum twist for bars, blanks and segments
Product
Blanks and
segments
Length of bar, 1,
or length plus height
of segment or blank,
L + H
mm
1 < 500
1 >500
( L t H ) <100
( L e H) >100
Maximum twist'
For any 100 mm
part of the length
mm
0.5
0.5
0.05
0.05 % of ( L +Hl
For any 500 mrn
part of the length
mm
-
2.5
0.05
I
* For segments, see figure I .
8
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k
T
l mm -7
Figure 4. Tolerance on shape of the convex thick edge
(see item (h) of 3.2)
l
E '
I
l mm or O. 5f
/IA
I t
lowest point
I
Figure 5. Tolerance band for the shape of the thin edge
f
7 Sampling
7.1 General
The materials shall be sampled as specified in 7.2 and 7.3.
NOTE. The sampling of mill, specified or multiple lengths i s not
specified but it i s recommended that, unless otherwise agreed,
one sample should be taken per 100 lengths or fraction thereof.
Specified or multiple lengths shortened by sampling are accepted
ac good delivery.
7.2 Material supplied in coils
One sample shall be taken per 10 coils or fraction thereof.
7.3 Blanks o segments
One sample shall be taken per 1000 blanks, or segments,
or fraction thereof.
8 Determination of hardness
The hardness shall be determined by means of either the
Brinell hardness test in accordance with BS 240, or the
Vickers hardness test in accordance with BS 427. Routine
measurements shall be made on the side face of the bar,
segment or blank.
In cases of dispute, the Vickers hardness test shall be the
referee method. The hardness shall be determined in the
cross-hatched area as shown in figure 6 and shall be
calculated as the average of two hardness measurements
made on each of the different samples, .e. a total of four
hardness measurements.
I
Figure 6. Measuring area for Vickers hardness
(referee method)
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, BSI BS* L 434 B5 M 1 b 2 4 b b 0072704 2 M
BS 1434 : 1985
Appendix A. Preferred nominal sizes
'
A.1 The heights of sections for commutator bars should be
selected either from the preferred heights given in table 12
or, for intermediate heights, in accordance with the Fi40
series of preferred num bers given in BS 2045.
I I
Table 12. Preferred nominal
heights, U, in mm, of sections
for commutator bars
6.3 22.4 80
7,1 25 90
8 28 1 O0
9 31.5 112
10 35.5 125
11.2 40 140
12.5 45 160
14 50 180
16 56 200
18 63
20 71
A.2 The diameters of finished commutators should be
selected either from the preferred diameters given in table 13
or, for intermediate diameters less than 50 mm, in accord-
ance with the R40 series of preferred numbers given in
BS 2045.
Table 13. Preferred nominal
diameters, in mm, of finished
commutators
12.5 80 500
14 90 560
16 1 O0 630
18 112 710
20 125 800
22.4 140 900
25 160 1 O00
28 1 80 1120
31.5 200 1250
35.5 224 1400
40 250 1600
45 280 1800
50 315 2000
56 355 2240
63 400 2500
71 450
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BSI B S* 1 4 3 4 85 E Lb24bb 0072705 4
Publications referred t o
BS 240 Method f or Brinell hardness test
BS 427 Method f or Vlckers hardness test
BS 1432 Copper f or electrical purposes. Strip wi t h drawn or rolled edges
BS 1433 Copper f or electrical purposes. Rod and bar
BS 2045 Preferred numbers
BS 601 7 Specification f or copper refinery shapes
IEC 356* Dimensions f or commutators and slip-rings
Referred t o i n the foreword only.
For information about BSI services relating to third party certification to suitable British Standard product specifications, schemes
for the registration of firms of assessed capability, testing and inspection facilities, please contact the Director, Quality Assurance
Division, BSI, Maylands Avenue, Hemel Hempstead, He& HP2 4SQ. Tel. Hemel Hempstead 31 1 1.
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BSI ESML 434 85 m L b 24669 O072706 b m
Amd. No. Date of issue
. BS 1434: i985
Text affected
Thls British Standard, having been prepared under the direction of
the Non-ferrous Metals Standards Committee, was published under
the authority of the Board of BSI and comes into effect on
28 February 1985.
@British Standards institution, 1985
First published February 1948
First revision December 1964
Second revision J une 1970
Third revision February 1985
ISBN O 580 14154 3
British Standards Institution
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body for the preparation of British Standards, It is the UK member
of the International Organization for Standardization and UK
sponsor of the British National Committee of the International
Electrotechnical Commission.
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Users of British Standards are reminded that copyright subsists in
all BSI publications. No part of this publication may be reproduced
in Qny form without the prior permission in writing of BSI. This
does not preclude the free use, in the course of implementing the
standard, of necessary details such as symbols and size, type or
grade designations. Enquiries should be addressed to the
Publications Manager, British Standards Institution, Linford Wood,
Milton Keynes MK14 6LE. The number for telephone enquiries is
0908 320033 and for telex 825777.
Contract requirements
A British Standard does not purport to include all the necessary
provisions of a contract. Users of British Standards are responsible
for their correct application.
Revision of British Standards
British Standards are revised, when necessary, by the issue either
of amendments or of revised editions. it is important that users of
British Standards should ascertain that they are in possession of
the latest amendments or editions. Information on all BSI
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Institution and gives details of new publications, revisions,
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making use of a British Standard, encounters an inaccuracy or
ambiguity, is requested to notify BSI without delay in order that
the matter may be investigated and appropriate action taken.
The following BSI references relate to the work on this standard:
Committee reference NFM/34 Draft for comment 82/77388 DC
Committees responsible for this British Standard
The preparation of this British Standard was entrusted by the
Non-ferrous Metals Standards Committee (NFM/-) to Technical
Committee NFM/34, upon which the following bodies were
represented:
British Non-ferrous Metals Federation
Copper Development Association
Inco Europe Limited
London Metal Exchange
Non-ferrous Metel Stockists
Coopted members
The following bodies were also represented in the drafting of the
standard, through sub-committees and panels:
Association of Bronze and Brass Founders
Associatlon of Supervisory and Executive Engineers
BEAMA Transmisclon & Distribution Association
BNF Metals Technology Centre
British Bronze & Brass Ingot Manufacturers
British Malleable Tube Fittings Association
British Valve Manufacturers' Association Ltd.
Copper Smelters' and Refiners' Association
Institute of British Foundrymen
International Tin Research Institute
London Transport Executive
Rotating Electrical Machines Association (BEAMA) Ltd
Telecommunication Engineering i31 Manufacturing Association
British Standards Institution a 2 Park Street London WIA 2BS . Telephone 01-629 9000 - Telex 266933
8502-6-1.4k-B r NFM/34 ~
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