The topic of my degree is based on the problematic hole dimension stability of the AHC+ commutator which happens due to multiple factors, that occur within the production process. The influences of the lead parameters in injection molding have been researched alongside other factors which occur in various operations of the parts production and the effect they have on the final dimension of the commutators hole. The dimension of the hole is an important characteristic. Applied to the shaft of the rotor, the commutator has to endure a high amount of revolutions. Alongside the revolutions, a momentum of twist of the commutator on the shaft also occurs.
The goal of my bachelor’s thesis was to study and position the correct ratio between injection molding and the occurring factors within the process of production. With the correct adjustments of the parameters of injection molding and the controlled overview of the factors within the process, we can then make commutators with stable dimensions without any mechanical defects and with the correct additives of materials to remove some of the excess material and ream the hole. Based on the analysis of the results that we received throughout the experimental work, we then optimized the parameters of injection molding. The products which we injected under such conditions were more fitting dimension-wise than the ones we made before.