Assembling and fitting commutators
Overview
This standard identifies the competences you need to select components and materials and to assemble commutator segments and separators, in accordance with approved procedures. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and type of components to be fitted and to check that they are in a safe and serviceable condition. In carrying out the operations, you will be required to follow laid-down procedures and specific assembly techniques. The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly positioned and free from damage.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken and to report any problems with the assembly activities, components or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying commutator assembly techniques and procedures. You will understand the commutator being assembled and its application and will know about the assembly techniques, tools and methods, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
P1 work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
P2 follow the relevant instructions, assembly drawings and any other specifications
P3 ensure that the specified components and tools are available and that they are in a usable condition in preparation for assembly
P4 assemble the components in their correct positions using appropriate methods and techniques
P5 secure the components using the specified connectors and securing devices
P6 check the completed assembly to ensure that all operations have been completed and it meets the required specification
P7 deal with problems within your control and report those that cannot be solved
P8 complete and store all relevant documentation in accordance with organisational requirements
P9 leave the work area in a safe condition on completion of the activities, as per organisational requirements
Knowledge and Understanding
You need to know and understand:
K1 how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
K2 the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy
K3 how to obtain and interpret drawings, planning sheets and records and other documents needed for the assembly activities
K4 the basic operating principles of the commutators being assembled
K5 the factors to be considered when choosing materials for commutator segments
K6 the methods of attaching armature wire to the commutator
K7 the methods used to fabricate commutator segments and the tolerances required
K8 the factors that influence the number of segments used
K9 the procedure for tinning commutator segments
K10 the methods used to machine the separators
K11 the correct procedures for the assembly of segments and insulated separators
K12 the precautions to be taken during assembly, with regard to longitudinal and radial position
K13 the factors that influence the choice of peening tools
K14 the procedures for fitting the assembly to mating components
K15 the methods used to check for electrical integrity of the sub-assembly
K16 the importance of locking fasteners and the type of fasteners to be used
K17 the visual checks and preparation requirements for the components to be used
K18 the methods, tools and equipment used to transport, handle and lift the components into position
K19 how to check that the tools/ equipment are within current certification dates, free from damage or defects, in a safe and usable condition and are configured correctly for purpose
K20 the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
K21 how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
1. Assemble the commutator by carrying out all of the following activities:
1.1 use the correct assembly drawings, specifications and job instructions
1.2 adhere to health and safety regulations, systems and procedures to realise a safe system of work
1.3 ensure that components are free from damage, foreign objects, dirt or other contamination
1.4 check that all tools and equipment are within calibration date, where appropriate
1.5 use safe and approved techniques to assemble and fit commutator components
1.6 leave the work are in a safe and tidy condition
2. Prepare and assemble commutators using all of the following:
2.1 commutator segments
2.2 sleeves
2.3 vee rings
2.4 locking devices
2.5 insulating segments
2.6 hubs
3. Use all of the following equipment and tools for the assembly operations:
3.1 multimeters
3.2 lathes
3.3 peening tools
3.4 dial test indicators
3.5 impedance testers
3.6 cutting tools
3.7 jigs
3.8 tinning equipment
3.9 shaft supports
3.10 clamps
4. Complete all of the following assembly procedures:
4.1 prepare materials (such as tinning segments)
4.2 assemble the components (such as segments and separators)
4.3 machine the assembled components
4.4 check mechanical integrity (such as longitudinal, radial position)
4.5 check electrical integrity (such as segment to segment, segments to hub)
5. Assemble rotating equipment to one of the following quality and accuracy standards:
5.1 organisational drawings and procedures
5.2 customer drawings and requirements
5.3 current industry standards, codes of practice and procedures
5.4 other international standards