Hello dear friend Alex,

However, I understand that you know exactly how my commutator system works...But your designing software may have pre-build models for commutators...as that is what you are using for your rendering.

Unfortunately, since there are non existing commutators like the ones I am using here...they must be built from scratch, even on a 3D Modeling Software.

Like I am doing at the moment...starting with a blank screen.

Regards

Ufopolitics

Reply to Message # 774

Hello, dear friend Ufopolitics,

Thank you for the clarification.
After reviewing your explanation, I realized that my previous 3D rendering still contained a fundamental error:
I had modeled the commutators as conventional motor commutators rotating with the shaft, while your design is actually a completely reversed commutation system.

Based on your latest description, I have now updated the engineering model to reflect the correct architecture:
• The two 32-segment commutators are stationary and mounted on the stator side.
 • The commutator contact surfaces are located on the INNER DIAMETER rather than the outer diameter.
 • The rotating brushes are mounted on the rotor assembly and sweep from the inside outward.
 • The slip rings rotate with the shaft and supply power to the rotating brush assemblies.
 • Each stationary commutator has 32 external output connections that feed the sequential coils.
 • The commutators no longer energize rotating armature coils as in a conventional brushed motor; instead, they function as stationary distribution rings while the brushes perform the scanning action.

Once I understood this reversal of the traditional motor architecture, the entire design became much clearer.
It explains why the commutator segments must remain stationary and why all 32 connections can be routed externally to the sequential coil system.

I have therefore produced a corrected 3D engineering rendering showing: NEW Type Bipolar Rotary Switch REVERSED Design


• Rotating slip-ring assemblies.
 • Rotating commutator brush carriers.
 • Stationary 32-segment commutators with internal contact surfaces.
 • External wiring exiting from the stator-mounted commutators.
 • The corrected current path from fixed brushes → rotating slip rings → rotating brushes → stationary commutators → sequential coils.

I think this updated interpretation appears to be much closer to your actual design intent.
Please review the corrected concept and let me know if the rotating brush arrangement, the stationary commutator geometry, and current-flow interpretation now match your intended operation.

Any additional dimensions or CAD details you can provide will help move the model closer to a true engineering representation of your Bipolar Rotary Switch.

Best regards, Alex

Hello All,

Hello dear friend @kampen ,

Ok, so it's been a "Marathon" to get all these 3D CAD SETUP completed...but, I think it would give you a much better understanding about this BIPOLAR COMM DRIVER.







In REALITY, I do not have much room to use the typical Horizontal Spring (Parallel to Brush) on the INNER COMMUTATOR ROTARY BRUSHES, because these types use too much LENGTH room .

Therefore, I will be using the PERPENDICULAR SPRING TYPE (as shown on this setup) because housing is MUCH SHORTER as Spring do not take Length Room at ALL.


Ok, so, because of saving time, I reuse the same type of Perpendicular Spring Type (to brush displacement line) for the Continuos Slip-Ring Brushes on BOTH INPUTS.

However, because there is plenty of room on BOTH END CAPS, we could use here the typical LENGTHY, PARALLEL SPRING Type of Brush Housing.


On above view, I took off the Negative Slip-Ring Brush...Just to show the TWO Commutating Brushes SWEEPING FROM INSIDE-OUT .

Please note BOTH BRUSHES ARE APART BY EXACTLY 180 DEGREES!! (Remember my previous post here that on a 32 Comm we have FOUR QUADRANTS ALTERNATED)

• Where TWO Quadrants are "Positive on Sequential Direction" meaning ASCENDING ORDER or 1, 2, 3, 4, 5, 6, 7, 8.
• And TWO Quadrants were 'Negative' or REVERSING ORDER on the Sequential Direction.

Meaning that when brushes are set at 180º, they FALL On SAME QUADRANTS (related to Direction of Sequence) as TRANSFER from one Quad to another THE SAME WAY.

I will try to make a Video Later On related to visualize my 3D CAD Program directly from my PC Screen....But, I have to set Camera (Cell Phone) because to manipulate the 3D Model on this MAYA Program I will need both hands.

Regards All,

PD: I want to THANK so much to @kampen for his efforts to help me building this 3D CAD Design!! As I hope now He will have a complete understanding of my Driver Setup Method.

Ufopolitics

Hello All,

Ok, so here is the Video I promised before...it is lousy on quality, because it was filmed from the PC Screen...it is not the camera.


But you could be able to see the whole 3D Assembly, moving it around and showing different angular views.

I am also showing the 'Basic Rotor Components', as I take off visibility of all other components blocking the view.

I hope now you will have a full understanding of how this driver will get built.

Regards All,

Ufopolitics

Reply to Message # 777 Update corrected RENDERING BIPOLAR Commutator
 
Dear friend Ufopolics,

First of all, thank you very much for taking the time to create and share these latest 3D CAD views and the video clip. 
They have greatly improved my understanding of the Bipolar Commutator Driver and helped clarify several aspects that were difficult to visualize from the earlier 2D drawings alone.

After studying your new renderings carefully, I can now clearly see the architecture of the system:
• The commutators are completely stationary and mounted to the stator structure.
 • The rotating brushes sweep the commutator segments from the INNER DIAMETER outward.
 • The positive and negative rotating brush assemblies are mounted directly to the rotor structure.
 • The slip rings rotate with the shaft and provide power to the rotating brushes.
 • All 32 output connections remain fixed on the stator side.
 • The positive and negative commutating brushes are positioned exactly 180° apart as required by your quadrant sequencing method.
 
The close-up views were especially helpful because they finally revealed the actual brush geometry and spring arrangement. 
I now understand why you selected the perpendicular spring design for the rotating commutator brushes.
 
Considering the limited radial space available inside the commutator ring, it is a very practical solution and significantly reduces the overall brush assembly length compared to conventional parallel-spring brush holders.
One aspect that particularly caught my attention is the elegant way the rotating brush carrier is integrated into the rotor assembly. 
The arrangement appears mechanically balanced and considerably lighter than having the segmented commutators rotating with the shaft. 
By keeping the 32-segment rings stationary, you avoid the challenge of bringing dozens of conductors through a rotating structure while maintaining direct access to all external connections.
 
To better visualize your latest development, I produced a new set of updated engineering renderings based on your recent CAD work.