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Commutator Profile Inspection and Analysis After Turning


This system analyzes the commutator contour and calculates geometrical characteristics, after a "filtering" process removes the slots from the original profile.
The bench references the armature shaft on V journals, reproducing the machining condition. 

  • Repetitive results, because the algorithms are always the same.
  • The measuring process is reproducible, because it is not influenced by the operator's judgment.
  • The measurements are obtained individually, by allowing the customer to tune the filtering parameters for every part number in an easy and clear manner.
  • The modular design allows for the implementation of subsequent standard options.
  • The self-learning retooling option is a big advantage when the unit is used to randomly measure a wide range of parts.
  • Software upgrades may be downloaded online by customers using their individual password.
  • Worldwide service support availability.
  • Post-process features available.
  • Connectivity for the use of network utilities in order to do data transfer, printing, and etc.
  • Collected measurement data can be transferred in QS-stat or Excel format for customized reporting.
  • It is possible to check the comprehensive system performance, in a scientific manner, using a master with shape errors (that is normally supplied with the bench).
  • This measurement system exploits the experience gained from a wide range of products supplied, to all the main manufacturers, worldwide. This experience provides a strong knowledge base and allows product features to grow according to common needs.
  • For the reasons mentioned above, this product is a recognized standard in its field.
  • A fixture version is available, suitable for applications with pick and place devices or robot loading.



  • BAR TO BAR: This is the vertical gap between the two adjacent edges on adjacent bars. All such gaps are calculated and the worst case is displayed; the typical tolerance is 3 µm. Values exceeding the tolerance have a dramatic influence on motor life.


  • BAR RISE - DELTA BAR: This is the TIR of each single bar. All the TIR's are calculated and the worst case is displayed; the typical tolerance is 5 µm. The value is related to the lathes tool status and indicates when a new tool is required. 


  • TIR: This is calculated considering all the bars. The typical tolerance is 10 µm. This value reveals if the shaft is bent and indicates potential problems with the part assembly process.
  • COMMUTATOR DIAMETER: The typical tolerance is 200 µm
  • ROUNDNESS: The typical tolerance is 5 µm




  • Angle between corresponding commutator and stack slots (commutation): This is performed if the stack slots are straight or if the section being inspected is referenced to a face of the shaft.
  • Stack TIR
  • Stack diameter
  • Shaft TIR in different sections
  • Bearing shoulder TIR



The standard bench can check all the armatures in the following range:

  • Journal diameter: 3-17 mm (1/8-11/16")
  • Commutator diameter: 60 mm (2 3/8") max
  • Stack lamination diameter: 120 mm (3 15/16") max
  • Distance between Journals: 300 mm (11 13/16") max
  • Special range fixtures are available on request
  • Part change is user friendly exploiting the self-learning retooling technique


This technique guides the operator in repositioning all the adjustable fixture subassemblies, whose positions are detected by sensors and displayed by virtual scales

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