Carbon brush automatic centering device based on temperature control air column and operation method

Abstract

The invention provides a carbon brush automatic centering device based on a temperature control air column and an operation method, and belongs to the technical field of motor collector rings. According to the device, an existing brush box is improved, an original constant-pressure spring is removed, five air columns are arranged at the bottom of the brush box, four air columns are distributed diagonally, and one air column is arranged in the middle. Each air column consists of an air sleeve, an air chamber and a piston rod, and the air chamber is filled with air; the top end of the piston rod is connected with a spring base, and a spring is installed between the spring base and a spring upper end seat, so that the springs of the five air columns act on the carbon brush together. The brush box is parallel to the collector ring, and the distance between the brush box and the collector ring is adjusted by rotating the hand frame, thereby ensuring that the carbon brush in the brush box is attached to the side surface of the collector ring. When the carbon brush deviates, the spring at the corresponding position can be stretched or compressed, and the deformation of the spring is the direct reflection of the deviation. By controlling the temperature of air in each air column, the volume of the air chamber is changed by utilizing the thermal expansion and cold contraction characteristics of air, and the piston rod is driven to stretch.

Description

Technical Field

[0001] This invention relates to the field of water turbine components, specifically to an automatic carbon brush centering device and its operation method based on a temperature-controlled air column. Background Technology

[0002] In rotating electromechanical equipment such as water turbines, reliable contact between carbon brushes and slip rings is crucial for power transmission. However, existing carbon brush alignment devices have significant drawbacks: slip rings inevitably wobble during rotation, and there is an assembly gap between the carbon brush and the brush holder. This wobble causes the carbon brush to move irregularly, tilt, or even become stuck within the brush holder. This unstable movement not only damages the effective contact area between the carbon brush and the slip ring, leading to increased contact resistance fluctuations and decreased power transmission efficiency, but also accelerates the wear of the carbon brush itself and scratches the inner wall of the brush holder, further widening the gap between the carbon brush and the brush holder. In severe cases, it can even cause the carbon brush to seize up, break, or generate spark discharge with the slip ring, directly threatening the safe and stable operation of the equipment. Traditional brush holder and constant pressure spring designs cannot correct carbon brush misalignment in real time, resulting in uneven wear, significantly shortened lifespan, and frequent downtime for maintenance, greatly increasing operating costs and downtime. Therefore, there is an urgent need for an automatic carbon brush alignment device that can dynamically adapt to slip ring movement deviations, provide stable contact pressure over a long period of time, and is easy to maintain. Summary of the Invention

[0003] The purpose of this invention is to design an automatic carbon brush alignment device based on a temperature-controlled air column, which overcomes the shortcomings of existing turbine carbon brush alignment devices, such as easy fatigue of constant pressure springs, insufficient dynamic compensation capability, and severe carbon brush wear. By combining temperature-controlled pneumatic drive with multi-point flexible support, dynamic and precise carbon brush alignment is achieved, ensuring reliable contact between the carbon brush and the slip ring.

[0004] To achieve the aforementioned technical features, the present invention aims to provide an automatic carbon brush alignment device based on a temperature-controlled air column, characterized in that it comprises a brush holder, a slip ring, and a brush box. The brush holder has a square groove on its side, the width of which matches the thickness of the outer wall of the brush box. The brush box is inserted along the square groove to ensure that the carbon brush inside the brush box is in close contact with the outer surface of the slip ring. The brush holder has small holes on its upper and lower surfaces, the diameter of which matches the bolts, and the hole spacing corresponds to the mounting holes of the brush holder base. A brush holder base for fixing the brush holder is fixedly installed at the location of the small holes by bolts. A brush holder is fixed on the brush holder base, and the brush box is fixedly installed at the end of the brush holder. The brush box is arranged parallel to the axis of the slip ring. An insulating washer is installed on the slip ring, and the size of the insulating washer is sufficient to ensure that the carbon brush installed in the brush box can fully contact the slip ring during rotation.

[0005] Preferably, 12 brush holder bases are evenly arranged on the side of the brush holder, and each brush holder base has four small holes and slots. Each small hole and slot is used to fix the brush holder base to the brush holder.

[0006] Preferably, the brush holder is equipped with a hand frame and a brush box at both ends, with the hand frame perpendicular to one end of the brush holder, and the other end of the brush holder having an opening that is fixed to the bottom of the brush box by an insulating screw.

[0007] Preferably, two slip rings are symmetrically arranged on the upper and lower sides of the slip ring bracket, and insulating washers are provided on both the upper and lower sides of the slip rings. A long screw is used to fix the slip ring bracket, insulating washers and slip rings.

[0008] Preferably, five sets of air columns are arranged inside the brush box, four of which are evenly distributed along the four diagonal lines of the bottom surface of the brush box so that the column wall is tangent to the two sides of the brush box, and one of which is centrally located; each set of air columns consists of an air sleeve, an air chamber and a piston rod, with an air pipe interface reserved on the side of the air chamber, and the top of the piston rod is connected to a spring base, with a countersunk hole in the center of the top surface of the spring base, and the spring is installed between the spring base and the upper end seat of the spring, with the upper end seat of the spring in close contact with the carbon brush.

[0009] Another aspect of the present invention provides a method for operating an automatic carbon brush alignment device based on a temperature-controlled air column, comprising the following steps: When the carbon brush shifts, it stretches or compresses the spring at the corresponding position. The deformation of the spring is a direct reflection of the shift. By controlling the temperature of the air in each air column chamber, the volume of the chamber is changed by utilizing the thermal expansion and contraction characteristics of air, which drives the piston rod to extend and retract. The movement of the piston rod drives the spring base to move, thereby dynamically adjusting the force applied by the spring to the carbon brush. The corrective force generated in this process causes the shifted carbon brush to automatically and dynamically return to its original center position or ideal contact state.

[0010] The present invention has the following beneficial effects: 1. This invention significantly extends the lifespan of carbon brushes and core components, reducing replacement frequency. In traditional structures, uneven carbon brush wear and sparking are the main reasons for component replacement, increasing consumable costs and impacting equipment utilization due to downtime. Using this invention effectively reduces the frequency of uneven carbon brush wear and sparking, ensuring uniform wear on the carbon brush end face; the pneumatic drive of the temperature-controlled air column uses flexible compensation, avoiding the impact and compression on the carbon brushes caused by traditional rigid spring compensation, thus reducing the risk of carbon brush breakage.

[0011] 2. This invention is adaptable to slip rings of different specifications. The number of air columns is adjustable: for small-diameter slip rings, the required carbon brushes are also smaller, so the number of air columns can be appropriately reduced; for large-diameter slip rings, the number of air columns can be increased without redesigning the overall structure. The temperature control range is adjustable: through parameter settings of an external temperature control module, the temperature adjustment range of the air chamber can be expanded or reduced to adapt to slip rings with different deviation ranges.

[0012] 3. This invention ensures efficient power output and reduces energy loss. Because the carbon brush is always in contact with the slip ring, there is only a very short time offset, but it can be quickly aligned, reducing contact resistance fluctuations and avoiding voltage drops caused by sudden increases in resistance.

[0013] 4. This invention improves operational safety and avoids potential safety hazards. In traditional structures, sparking, carbon powder buildup, and localized overheating not only affect equipment operation but can also lead to safety risks. This invention's dynamic alignment ensures seamless contact between the carbon brushes, reducing the spark rate and preventing serious fires caused by sparks igniting the carbon powder. Attached Figure Description

[0014] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0015] Figure 1 This is a schematic diagram of the present invention.

[0016] Figure 2 This is the front view of the present invention.

[0017] Figure 3 This is a top view of the present invention.

[0018] Figure 4 This is a side view of the present invention.

[0019] Figure 5 This is a schematic diagram of the brush holder of the present invention.

[0020] Figure 6 This is a cross-sectional view of the brush holder structure of the present invention.

[0021] Figure 7 This is a partial cross-sectional view of the brush holder structure of the present invention.

[0022] Figure 8 This is a side view of the brush holder structure of the present invention.

[0023] Figure 9 For the present invention Figure 8 AA view of the brush grip structure.

[0024] Figure 10 For the present invention Figure 8 Top view of the brush grip structure.

[0025] Figure 11 For the present invention Figure 8 Side view of the brush grip structure.

[0026] In the diagram, brush holder 1, slip ring 2, bolt 3, square groove 4, brush box 5, small hole groove 6, long bolt 7, insulating washer 8, slip ring bracket 9, hand frame 10, brush holder base 11, insulating screw 12, brush holder 13; Carbon brush 501, upper spring seat 502, spring 503, spring base 504, piston rod 505, air chamber 506, air sleeve 507, countersunk hole 508, air pipe interface 509. Detailed Implementation

[0027] The present invention will be further described in detail below through specific embodiments. These embodiments are intended to enable those skilled in the art to gain a more comprehensive understanding of the present invention, but do not limit the invention in any way.

[0028] Example 1: See Figure 1-11 An automatic carbon brush alignment device based on a temperature-controlled air column is characterized by comprising a brush holder 1, a collector ring 2, and a brush box 5. The brush holder 1 has a square groove 4 on its side, the width of which is adapted to the thickness of the outer wall of the brush box 5. The brush box 5 is inserted along the square groove 4 to ensure that the carbon brush 501 inside the brush box 5 is in contact with the outer circular surface of the collector ring 2. The brush holder 1 has small hole grooves 6 on its upper and lower surfaces. The diameter of the small hole grooves 6 matches that of bolts 3, and the hole spacing corresponds to the mounting holes of the brush holder base 11. The location of the small hole grooves 6 is fixedly installed with the brush holder base 11 for fixing the brush holder by bolts 3. A brush holder 13 is fixed on the brush holder base 11, and the brush box 5 is fixedly installed at the end of the brush holder 13. The brush box 5 is arranged parallel to the axis of the collector ring 2. An insulating washer 8 is installed on the collector ring 2. The size of the insulating washer 8 is to ensure that the carbon brush 501 installed in the brush box 5 can make full contact with the collector ring 2 during rotation. This invention redesigns the brush holder, removing the constant pressure spring structure from the traditional brush holder and instead constructing a composite support system of "temperature-controlled air column + spring assembly". This system can capture the offset signal of the carbon brush caused by radial runout or axial movement of the slip ring in a very short time, and achieve precise compensation through temperature control drive, ensuring that the carbon brush and slip ring always maintain stable contact.

[0029] Furthermore, 12 brush holder bases 11 are evenly arranged on the upper and lower sides of the brush holder 1. Each brush holder base 11 has four small holes 6, and each small hole 6 is fixed to the brush holder base 11 by bolts 3. Through the above installation structure, the brush holder base 11 can be reliably fixed and installed.

[0030] Furthermore, a hand bracket 10 and a brush box 5 are respectively installed at both ends of the brush holder 13. The hand bracket 10 is perpendicular to one end of the brush holder 13, and the other end of the brush holder 13 has an opening that is fixed to the bottom opening of the brush box 5 by an insulating screw 12. Through the above installation structure, the brush holder 13 can be reliably installed.

[0031] Furthermore, two slip rings 2 are symmetrically arranged on the upper and lower sides of the slip ring bracket 9, and insulating washers 8 are provided on both the upper and lower sides of the slip ring 2. The long screw 7 is used to fix the slip ring bracket 9, the insulating washers 8, and the slip rings 2. The above structure enables the assembly and connection of the slip ring bracket 9, the insulating washers 8, and the slip rings 2.

[0032] Furthermore, five sets of air columns are arranged inside the brush box 5, four of which are evenly distributed along the four diagonal lines of the bottom surface of the brush box so that the column walls are tangent to the sides of the brush box, and one is centrally located; each set of air columns consists of an air sleeve 507, an air chamber 506 and a piston rod 505, with an air pipe interface 509 reserved on the side of the air chamber, and the top of the piston rod 505 is connected to a spring base 504. A countersunk hole 508 is provided in the center of the top surface of the spring base 504, and the spring 503 is installed between the spring base 504 and the upper spring seat 502, with the upper spring seat 502 in close contact with the carbon brush 501.

[0033] Furthermore, the bottom inner wall of the brush box has five sets of circular mounting holes pre-set, with the hole diameter matching the outer diameter of the air sleeve, forming an array of four diagonally distributed holes and a centrally distributed hole. The air sleeve is inserted into the mounting holes through an interference fit. Each air sleeve is equipped with an air chamber and a piston rod. The air chamber is a hollow cylindrical structure, filled with dry compressed air, and has a pre-reserved air pipe interface on the side. The lower end of the piston rod is inserted into the air chamber through a sliding fit, and the upper end is fixedly connected to the spring base. A countersunk hole is provided in the center of the top surface of the base to embed a miniature piezoresistive sensor. The top surface of the sensor is flush with the base, ensuring that the annular groove at the lower end of the spring directly presses on the sensor. The spring is vertically arranged between the spring base and the upper spring seat. The lower end of the spring is interference-fitted with the annular groove on the spring base, and the upper end fits with the groove of the same specification at the bottom of the upper spring seat. Both ends are fixed by spot welding. The upper spring seat fits against the carbon brush, ensuring that the five sets of springs provide uniform support pressure to the carbon brush.

[0034] Example 2: Another aspect of the present invention provides a method for operating an automatic carbon brush alignment device based on a temperature-controlled air column, comprising the following steps: When the carbon brush 501 shifts, it stretches or compresses the spring 503 at the corresponding position. The deformation of the spring 503 is a direct reflection of the shift. By controlling the temperature of the air in each air column chamber 506, the volume of the chamber 506 is changed by utilizing the thermal expansion and contraction characteristics of air, which drives the piston rod 505 to extend and retract. The movement of the piston rod 505 drives the spring base 504 to move, thereby dynamically adjusting the force applied by the spring 503 to the carbon brush. The corrective force generated in this process causes the shifted carbon brush 501 to automatically and dynamically return to its original center position or ideal contact state.

[0035] Working principle of this invention: Specifically, when the high-speed rotation of the slip ring causes radial deviation or axial movement, the carbon brush will tilt due to the assembly gap within the brush holder. At this time, the five sets of springs in contact with the bottom surface of the carbon brush will immediately experience uneven force; the spring on the offset side is compressed, and the spring on the opposite side is stretched. The pressure sensor integrated into the spring base can transmit the force difference signal to the external temperature control unit. After receiving the signal, the temperature control unit will initiate precise temperature control for the air column at different positions: for the air column chamber on the offset side, the electric heater heats up the air chamber, causing the dry air inside to expand and push the piston rod out, moving the spring base upward, thereby increasing the support pressure of the corresponding spring; at the same time, the air column chamber on the opposite side activates a miniature cooling fan to cool down, causing the chamber volume to shrink and the piston rod to retract, reducing the pressure of the corresponding spring. This directional pressure difference will form a corrective force along the normal direction of the carbon brush center, pushing the carbon brush back to the geometric center, which can effectively avoid contact gaps between the carbon brush and the slip ring during dynamic deviation.

[0036] Although the preferred embodiments of the present invention have been described above in conjunction with the accompanying drawings, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many specific modifications under the guidance of the present invention without departing from the spirit of the invention and the scope of protection of the claims, and these modifications all fall within the scope of protection of the present invention.

Claims

1. An automatic carbon brush centering device based on a temperature-controlled air column, characterized in that, The assembly includes a brush holder (1), a collector ring (2), and a brush box (5). The brush holder (1) has a square groove (4) on its side, the width of which matches the thickness of the outer wall of the brush box (5). The brush box (5) is inserted along the square groove (4) to ensure that the carbon brush (501) inside the brush box (5) fits against the outer surface of the collector ring (2). The brush holder (1) has small hole grooves (6) on its upper and lower surfaces. The diameter of the small hole grooves (6) matches that of the bolts (3), and the hole spacing corresponds to the mounting holes of the brush holder base (11). The small hole grooves (6) are located in... The part is fixedly installed with a brush holder base (11) for fixing the brush holder by bolts (3); a brush holder (13) is fixed on the brush holder base (11), and a brush box (5) is fixedly installed at the end of the brush holder (13); the brush box (5) is arranged parallel to the axis of the collector ring (2); an insulating washer (8) is installed on the collector ring (2), and the size of the insulating washer (8) is to ensure that the carbon brush (501) installed in the brush box (5) can make full contact with it during the rotation of the collector ring (2).

2. The automatic carbon brush centering device based on a temperature-controlled air column according to claim 1, characterized in that, The brush holder (1) has 12 brush grip bases (11) evenly arranged on the upper and lower sides. Each brush grip base (11) has four small holes (6). Each small hole (6) is fixed to the brush holder (11) by bolts (3).

3. The novel end-face contact structure of carbon brush and slip ring according to claim 1, characterized in that: The brush holder (13) is equipped with a hand frame (10) and a brush box (5) at both ends. The hand frame (10) is perpendicular to one end of the brush holder (13). The other end of the brush holder (13) has an opening that is fixed to the bottom opening of the brush box (5) by an insulating screw (12).

4. The novel end-face contact structure of carbon brush and slip ring according to claim 1, characterized in that: Two collector rings (2) are symmetrically arranged on the upper and lower sides of the collector ring bracket (9), and insulating washers (8) are provided on both the upper and lower sides of the collector rings (2). The long screw (7) is used to fix the collector ring bracket (9), the insulating washers (8) and the collector rings (2).

5. The novel end-face contact structure of carbon brush and slip ring according to claim 1, characterized in that: Five sets of air columns are arranged inside the brush box (5), four of which are evenly distributed along the four diagonal lines of the bottom surface of the brush box so that the column wall is tangent to the two sides of the brush box, and one of which is set in the center. Each set of air columns consists of an air sleeve (507), an air chamber (506) and a piston rod (505). An air pipe interface (509) is reserved on the side of the air chamber. The top of the piston rod (505) is connected to the spring base (504). A countersunk hole (508) is provided in the center of the top surface of the spring base (504). The spring (503) is installed between the spring base (504) and the upper spring seat (502). The upper spring seat (502) is close to the carbon brush (501).

6. The operating method of the automatic carbon brush alignment device based on a temperature-controlled air column as described in any one of claims 1-5, characterized in that, Includes the following steps: When the carbon brush (501) deviates, it will stretch or compress the spring (503) at the corresponding position. The deformation of the spring (503) is a direct reflection of the deviance. By controlling the temperature of the air in each air column chamber (506), the volume of the chamber (506) is changed by utilizing the thermal expansion and contraction characteristics of air, which drives the piston rod (505) to extend and retract. The piston rod (505) moves, causing the spring base (504) to move, thereby dynamically adjusting the force applied by the spring (503) to the carbon brush; the corrective force generated in this process causes the offset carbon brush (501) to automatically and dynamically return to its original center position or ideal contact state.

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