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:
- work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble the components in their correct positions using appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and it meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others, as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- how to obtain and interpret drawings, planning sheets and records and other documents needed for the assembly activities
- the basic operating principles of the commutators being assembled
- the factors to be considered when choosing materials for commutator segments
- the methods of attaching armature wire to the commutator
- the methods used to fabricate commutator segments and the tolerances required
- the factors that influence the number of segments used
- the procedure for tinning commutator segments
- the methods used to machine the separators
- the correct procedures for the assembly of segments and insulated separators
- the precautions to be taken during assembly, with regard to longitudinal and radial position
- the factors that influence the choice of peening tools
- the procedures for fitting the assembly to mating components
- the methods used to check for electrical integrity of the sub-assembly (such as segment to segment, segments to hub)
- the importance of locking fasteners and the type of fasteners to be used
- the visual checks and preparation requirements for the components to be used
- the methods, tools and equipment used to transport, handle and lift the components into position
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
the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Assemble of the commutator by carrying out all of the following activities:
- use the correct assembly drawings, specifications and job instructions
- adhere to health and safety regulations, systems and procedures to realise a safe system of work
- ensure that components are free from damage, foreign objects, dirt or other contamination
- check that all tools and equipment are within calibration date, where appropriate
- use safe and approved techniques to assemble and fit commutator components
- leave the work are in a safe and tidy condition
Prepare and assemble commutators using all of the following:
- commutator segments
- sleeves
- vee rings
- locking devices
- insulating segments
- hubs
Use all of the following equipment and tools for the assembly operations:
- multimeters
- lathes
- peening tools
- dial test indicators
- impedance testers
- cutting tools
- jigs
- tinning equipment
- shaft supports
- clamps
Complete all of the following assembly procedures:
- prepare materials (such as tinning segments)
- assemble the components (such as segments and separators)
- machine the assembled components
- check mechanical integrity (such as longitudinal, radial position)
- check electrical integrity (such as segment to segment, segments to hub)
Assemble rotating equipment to one of the following quality and accuracy standards:
- organisational drawings and procedures
- customer drawings and requirements
- current industry standards, codes of practice and procedures
- other international standards