Many DC commutator motors are widely used in automobiles. In recent years, as compact and high output DC motors have been developed due to advanced technology, the faster the rotational speed is required and the commutation arc causes a high rate of wear/erosion of brush and commutator. Therefore, it is important how the motor speed influences commutation phenomena such as arc duration, residual current and erosion and wear of commutator and brush in order to achieve high reliability and extensive lifespan. In this paper waveforms of commutation voltage and current are measured at the rotation speed of 1000 to 5000min-1and the relation between rotation speed and arc duration / residual current is obtained. In addition long term tests are carried out at the rotation speed of 1000 to 5000min-1 the change of arc duration and effective commutation period is examined during the test of 20hours. Further, brush wear is evaluated by the difference of brush length between before and after test. Consequently, it can be made clear that as the speed increases, the effective commutation period decreases and the arc duration is almost same at the speed up to 3000min-1 and is around 42µsec.

We proposed a new electric contact device that suppresses the arc phenomena. The functions of electric contacts are divided into energizing and switching for arc suppression. Switching contacts consist of multielectrodes and each electrode current is suppressed by the series resistance. For realization of multicontacting, cantilever beam array electrodes were formed on a silicon substrate using micro-electromechanical systems (MEMS) technology. The finite element method was used to optimize the structure. The fabrication process of the cantilever was examined. Au-Au contact current of 0.97 A was broken without arc ignition.

This paper reports the development of a lead-free brush material for a high-load starter. These brushes are used in much more extreme conditions -- at the PV-value (the product of brush contact pressure and sliding velocity) approximately three times that of other starter brushes, and double the electrical current density. The major technical requirement of this development was to decrease the electrical wear in brushes caused by commutation sparking. We developed a brush material that reduces electrical wear by adding zinc phosphate. Because zinc phosphate can improve the lubricity at high-temperature and the contact stability of brushes, the developed brush reduces commutation sparks. The life of the developed brush is about 1.5 times longer than that of conventional brushes containing lead.

At the sliding contact of brush and rotating slip-ring or commutator, it has been recognized that the brush wear is influenced by brush pressure, current density and atmosphere nearby contact part. However, little is known about the relation between brush wear and atmosphere condition in detail. In this paper, the experiments are carried out with a great attention to the effect of surrounding temperature and humidity on brush wear. The sliding part of brush and slip-ring is put on the sealed box and the atmosphere in the sealed box is kept on the specified condition by temperature and humidity control system. The brush wear, contact voltage drop and slip-ring surface morphology are observed after the sliding test. From these results, in both cases of the high humidity (nearby 80%) and low humidity (nearby 20%), the brush wear are large. And the brush wear rate is the lowest around 60% relative humidity. However, the characteristics of brush wear under the 15C is not similar to others. When the surrounding temperature is changed, in case of the 20% humidity, the brush wear increases with increasing surrounding temperature. On the other hand, in case of 80% humidity, the brush wear increases with decreasing surrounding temperature. Consequently, the results clearly shows that the temperature and humidity not only affect the brush wear but also change the condition of the film formation on slip-ring.

Electromagnetic relays were developed in the first half of 19th century. At the beginning, they have been mainly used for telecommunication systems, afterwards, their uses were expanded, they have been applied to various systems such as industry products, traffic control equipment, household appliances and so on. During this time, international standardization on them became active, Japan took part in the auxiliary relay committee in the International Electrotechnical Commission (IEC). Recently, Japan is playing an important role in the committee activities. In this paper, transition and the present circumstance on technical trends of the electromagnetic relays and their activities on international standardization are described, talking about some future prospects.

Authors have studied degradation phenomenon on electrical contacts under the influences of an external micro-oscillation. A new micro-sliding mechanism 2 (MSM2) has developed, which provides micro-sliding driven by a piezo-electric actuator and elastic hinges. The experimental results are obtained on “minimal sliding amplitudes” to make resistances fluctuate on electrical contacts under some conditions which are three types of inputwaveform (sinusoidal, rectangular, and impulsive) and three levels of frictional force (1.6, 1.0, and 0.3 N/pin) by using the MSM2. The dynamical characteristics are discussed under the conditions. The simple theoretical model on the input signal and the output of the mechanism is built and the theoretical expressions from the model are obtained. A natural angular frequency (ω0=12600[s-1]) and a damping ratio (ζ=0.03[-]) are evaluated using experimental dynamical responses. The waveforms of inputs and outputs are obtained and the characteristics between inputs and outputs are also obtained on the theoretical model using the above. The maximal gain between the input and the output in rectangular or impulsive (24.4) is much larger than that (0.0) in sinusoidal. The difference on the output-accelerations between in sinusoidal and in rectangular (impulsive) is discussed. It is shown that it is possible to cause the degradation phenomenon in sinusoidal only when the output displacement are enlarged. It is also shown that it is possible to cause the phenomenon in rectangular or in impulsive, in addition to the above, when the external force has sharper rising and falling waveforms even if the displacement and the frequency of the force is small. The difference on the output-amplitudes between in rectangular and in impulsive is discussed. It is not clear that there is the difference between the effect in rectangular and that in impulsive. It is indicated that it is necessary to discuss the other causes, for instance, another dynamical, thermal, and chemical process.

A new scheme for evaluation of shapes of pips and craters formed by arc discharges on electrical contact surfaces is proposed. Measuring a height of a pip or a depth of a crater as well as an average diameter thereof with a scanning laser microscope and then putting a plot having the measured values as its vertical and horizontal coordinates enable us to numerically and briefly evaluate shapes of those pips and craters on arc-damaged contact surfaces. Some exemplary results obtained by this evaluation scheme are presented here.

Some experimental results on the contact phenomena that have been observed with electrical contacts operated to break an inductive DC load current in nitrogen atmosphere and in air (laboratory atmosphere) are presented. When Ag, Pd and Cu contacts were operated to break an inductive DC load current in the range of 1.0 A to 3.0 A in nitrogen atmosphere, more stable contact resistance characteristics were obtained, as compared to the case where operated in air, or at least the occurrence of unstableness and increase in contact resistance was delayed. The arc duration in nitrogen atmosphere became shorter in general than in air, especially with the Pd and Cu contacts. Voltage waveforms of arc discharges in the Ag and Pd contacts operated in nitrogen atmosphere showed a relatively clear step-like transition from the metallic phase to the gaseous phase as compared to the case where operated in air, while the Cu arcs did not show such significant differences due to the surrounding atmosphere. Although any apparent differences on the contact surface conditions in connection with the surrounding atmosphere were not clearly observed after the switching operations, the anode mass change characteristics were found to be more significantly affected by the difference of surrounding atmospheres than the cathode mass changes. The obtained experimental results suggest that the difference in the surrounding atmosphere introduce some difference in the anode surface morphology, possibly through the deposition of arc products in different deposition patterns, which will then result in differences in the contact resistance characteristics.

This letter presents the results of Auger analysis of surface products by steady arc on Ag/Pd contacts. Black products formed on Ag contact surfaces, which make contact resistance high and unstable, are silver oxide. In the case of Pd contacts, contact resistance of which remains low and stable, white-colored products seen after operations seem to be powdery palladium.

In this letter the formation of palladium-oxides on AgPd 70 and AgPd50 contacts caused by mechanical switching actions is reported. Further, palladium-oxides are found to show non-linearity of contact resistance when contact potential drop gets over about 0.3 V.

In this letter, it is confirmed that contact resistance of AgPd70 contacts through mechanical break-make operations remains low despite of palladium-oxides formed on the electrode surfaces. Also, material transfer due to the difference of hardness is found to influence the formation of the products.

The authors have developed a mechanism that applies real vibration to electrical contacts by hammering oscillation in the vertical direction similar to that in real cases, and they have studied the effects of micro-oscillation on the contacts using the mechanism. It is shown that the performance of the hammering oscillation mechanism (HOM) for measuring acceleration and force is superior to that of other methods in terms of the stability of data. Using the mechanism, much simpler and more practical protocols are proposed for evaluating acceleration, force, and mass using only the measured acceleration. It is also indicated that the relationship between the inertial force generated by the hammering oscillation mechanism and the frictional force in electrical devices attached on a board is related to one of the causes of the degradation of electrical contacts under the effect of external micro-oscillation.

Arc discharge between electrodes of relays and switches often causes contact surface damage through material transfer and arc erosion. Especially, material transfer sometimes occurs and brings serious failure even under lower load that is quite smaller than the minimum arc current value of contact material. In this paper, contact surface configuration, material transfer, and arc erosion characteristics of Ag and AgPd 60 contacts were experimentally studied after 0.5 or 1 million switching operations at various load levels. The followings can be made clear. Firstly, it was confirmed that the arcs and material transfer occurred even under such current that was lower than the minimum arc current. Therefore, the definition of the arc occurrence boundary current was newly determined. Secondly, the relation between load conditions (current and power supply voltage) and contact surface configuration (craters and pips) caused by material transfer was studied. The arc erosion behaviors of tested samples could be classified into two types: material transfer type and wear-out type. As one of the primary factors of transition from the former type to the latter one, contact activation was considered. The influences of load conditions and organic gas emitted from relay structure on arc characteristics was experimentally examined. The results indicated that load current greatly influenced the amount of material transfer and that power supply voltage affected the occurrence of the wear-out type significantly. The activation behavior of the contact surface could be found through observing the bridge voltage waveform.

The surface film of a slip ring is important for the sliding contact phenomenon. The surface film is affected by atmospheric temperature, humidity and air pressure. The main objective of our study is to examine the effect of oxygen gas on the sliding contact phenomenon. In the present experiment, we examined the contact voltage drop for continuous sliding when the atmosphere is changed from low pressure to atmospheric pressure by introducing oxygen (O2 20%+N2 80%) or nitrogen gas. As a result, the contact voltage drop increases rapidly with increasing gas pressure, and its fluctuation also becomes large. These phenomena are observed in both cases of oxygen (O2 20%+N2 80%) and nitrogen introduction. The results clearly show that the sudden increase of contact voltage drop is affected by factors other than the oxide film. Actually, the oxide film is not formed in the nitrogen atmosphere. Furthermore, the frictional coefficient of carbon and copper ring is changed at ambient atmosphere. It is inferred from these data that the contact voltage drop may be affected by the frictional coefficient. When the gas pressure decreases again, the contact voltage drop does not suffer from the effect of ambient gas. Therefore, only the resistance of the oxide film appears to affect contact voltage drop. In this paper, the effect of sliding contact phenomenon on the contact voltage drop by gas adsorption and film generation was examined.

Sliding contact behavior is important in the mechanism of collecting current. In this study, the effect of ambient gas including an inert gas on surface film formation and on the contact voltage drop was examined, changing the atmosphere from low pressure to atmospheric pressure. Furthermore, the sliding surface state was observed using SEM, EDX and XPS analyzers after the test operation. As a result, at the sliding contact in an inert gaseous environment (nitrogen and argon), it was confirmed that the contact voltage drop tends to increase. However, it was clarified that any chemically generated surface film is difficult to detect in the inert gas environment by qualitative analysis. On the basis of these results, we suggest the existence of physically adsorbed surface film. The relationship between inert gases and sliding contact phenomena is discussed.

Arc and contact resistance characteristics of Ag and Pd contacts were determined in several kinds of dielectric liquids, such as distilled water, methanol and n-hexane, under the inductive load condition. The experimental results showed that arc discharge types are dependent on dielectric liquids. A steady arc develops in air under this test condition. However, it was found that not the steady arc but the showering arc occurs in distilled water and methanol at a low load current. It was demonstrated that this phenomenon is caused by the high capacitance generated by the ambient dielectric liquid. Also, in almost all cases, the contact resistance behavior in dielectric liquids is satisfactory because metal spots remain on the contact surface. However, in n-hexane, the contact resistance tends to deteriorate, particularly for the Ag contact, with increasing load current. It seems that the deterioration of contact resistance is caused by carbon included in n-hexane.

The electromagnetic interference (EMI) induced by steady arc has been demonstrated to be dependent on arc voltage fluctuation when the arc transfers from the metallic phase to the gaseous phase. In order to give the physical understanding of this arc voltage fluctuation and EMI, several typical materials, such as Ag, Cu and Zr, were tested and their arc behavior was determined and compared. The experimental results indicated that the arc behavior, in particular the arc voltage fluctuation in the moment that metallic phase transfers to the gaseous phase was different for different materials. Based on the test results and former investigations, a plausible mechanism is proposed for understanding these phenomena.