To replace the segment pack (Copper bars and mica segments banded together), mica v-rings, and mica tube made to fit the original steel cap (as supplied by the customer) with the same extensions (within tolerance) as the original segment pack sample (sent in by the customer) so that the customer can perform the assembly, curing/seasoning/tightening processes, and other final procedures (customer assuming all liability for manufacturing/assembly and warranty aside from actual fit of the parts) and designed to meet or exceed design specifications on electrical and mechanical requirements if the customer follows the proper procedures in completing the unit.

Any unit built using no parts from the original sample unit or a unit produced from dimensions only.  As always the unit must meet or exceed electrical and mechanical design specifications.  Units can be produced as prototypes, small volume, and/or mass produced items to original specifications, custom designs, and/or reproductions of originals.

An application specific testing process that merely subjects the commutator or slip ring unit to a prescribed speed over and above the maximum rated speed of the motor (typically at ambient temperature) with specified limits to the amount of individual bar variences and total indicated runout as measured on the brush riding surface.  This testing procedure is often considerably less expensive than SPIN SEASONING while subjecting the commutator to a significant overspeed situation that would likely expose any potential for bar movement without necessitating the additional time and labor required by most SPIN SEASONING specifications.  Typical HIGH SPEED SPIN TESTS are performed between 125% and 150% of rated maximum rpm with less than .0002 individual bar movement and less than .0005 total indicated runout from bar movement (actual testing requirements may vary).  HIGH SPEED SPIN TESTING is highly recommended for any/all MOLDED CONVERSIONS, high performance commutators, and/or commutators that might be considered “high rpm” units.

To completely redesign an original molded type commutator with a steel & mica type commutator (often refillable) to meet the fit, form, function, application, rpm requirements, and temperature range of the original unit and meet or exceed design specifications and other mechanical requirements.

Original Equipment Manufacturer.

To completely replace all insulation materials and Copper bars (commutators) or Bronze rings (slip rings) while reusing the original steel parts, balance rings, and/or any non-electrical related materials and meet or exceed design specifications on electrical and mechanical requirements.

To completely replace all insulation materials while reusing the original Copper bars (commutators) or Bronze rings (slip rings) as well as the original steel parts, balance rings, and/or any other non insulating material and meet or exceed design specifications on electrical and mechanical requirements.

To completely fix the immediate problem on a commutator or slip ring that is otherwise in good condition with a reasonable amount of brush surface life remaining and meet or exceed design specifications on electrical and mechanical requirements.

An application specific process in which a combination of heating and cooling while spinning (all temperatures, times, speeds, etc are specified per application and/or design and typically go above and beyond what the unit should actually be subjected to when placed in service) designed to replicate the actual heat cycling and rotation that an electric motor goes through in normal operation so that any potential for any bar movement brought about by the differential rates of expansion and contraction of Copper bars and Steel parts in the commutator is virtually eliminated.

This procedure can be expensive to perform in some cases, but it can be vital for critical applications and other high performance commutators that otherwise might place rewind shops at risk of paying thousands of dollars in repairs from bar movement problems that have been seen in units that do not undergo this procedure when specified.  The best time to spin season a commutator is prior to installation and winding of the armature since the commutator should always be stable prior to subjecting it to these procedures.

It has been said that there can be additional advantages to spin season the entire armature after winding (usually in mass production situations only), but there are many shops that lack the equipment and/or expertise to perform these potentially hazardous procedures, so it is typically best to spin season the commutator alone rather than risk having to replace expensive coils should the commutator bars move after the armature is wound.