Device and method for electrically charged replacement of brushes

Abstract

This invention discloses a device and method for live brush replacement, aiming to overcome the difficulty of live brush replacement. The invention includes an insulated handle, a push rod, and a base. A movable brush holder is mounted on the base, and brushes are mounted on the brush holder. The insulated handle is mounted on the base and has a top block and a positioning post. One end of the push rod is supported on the top block, and the positioning post abuts against the base. Rotating the insulated handle causes the top block to push the push rod to move, and the push rod abuts against the brush, separating the positioning post from the base. Pulling the insulated handle outward causes the positioning post to abut against the brush holder, pulling the brush holder and brushes outward together. Live brush replacement is convenient.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and more specifically, to a device and method for replacing brushes while the circuit is energized. Background Technology

[0002] As a key component of the rotor excitation system in large synchronous generators, the brush is responsible for transmitting DC excitation current from stationary components to rotating components. With the increasing demands of the power grid on generator units, more and more contract terms require the ability to replace brushes while the generator is energized. This allows for brush replacement without shutting down the generator, addressing the need for brush replacement under energized conditions. However, currently, there is no dedicated device for driving brush replacement, which presents challenges for energized brush replacement. Summary of the Invention

[0003] This invention overcomes the difficulty of replacing brushes while they are energized, and provides a device and method for replacing brushes while they are energized, which facilitates the replacement of brushes while they are energized.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a device for replacing brushes while energized, comprising an insulating handle, a push rod, and a base. A movable brush holder is installed on the base, and a brush is installed on the brush holder. The insulating handle is installed on the base, and a top block and a positioning post are provided on the insulating handle. One end of the push rod is supported on the top block, and the positioning post abuts against the base. Rotating the insulating handle causes the top block to push the push rod to move, and the push rod abuts against the brush, separating the positioning post from the base. Pulling the insulating handle outward causes the positioning post to abut against the brush holder, pulling the brush holder and brush outward together.

[0005] During normal operation, the brush is mounted on the brush holder and, under the action of the constant pressure spring, the brush is always in contact with the slip ring to conduct electricity. The push rod separates from the brush, ensuring that the constant pressure spring can push the brush towards the slip ring. The positioning post abuts against the base, realizing the positioning of the insulated handle and the base in the direction of movement.

[0006] Over time, wear between the brushes and slip rings increases, necessitating regular brush replacement. Brush replacement can be performed without disconnecting the power supply; the work can be done while the power is on. First, rotate the insulating handle to move the push rod, which then engages with and locks the brush. Simultaneously, the positioning pin separates from the base, and the insulating handle unlocks from the base. Pull the insulating handle outwards, engaging the positioning pin against the brush holder, pulling the brush holder and brush together outwards. Disconnect the terminals connected to the brush. Rotate the insulating handle to separate the push rod from the brush. Remove the old brush and replace it with a new one. After the new brush is installed, rotate the insulating handle to move the push rod, engaging the brush and locking it in place. Connect the terminals to the new brush. Push the insulating handle inwards, pushing the brush holder and brush together towards the motor's slip rings. Once the brush holder is in place, rotate the insulating handle to separate the push rod from the brush, while the positioning pin engages with the base for restraint. This device, which allows for live brush replacement, facilitates the live brush replacement operation.

[0007] Preferably, the base is provided with a positioning plate, the positioning plate is provided with a positioning groove and a clearance groove, the clearance groove passes through the positioning plate, and both the positioning groove and the clearance groove are adapted to the positioning post. The positioning post is placed in the positioning groove to realize the positioning of the insulated handle. The positioning post passes through the clearance groove and abuts against the brush holder to push the brush holder to move.

[0008] The positioning plate positions the brush holder and the insulating handle. When the brush is working normally, the positioning pin is in the positioning groove, preventing the insulating handle from rotating. This keeps the push rod in a separated position from the brush, ensuring the constant pressure spring can move the brush and that the brush remains in contact with the slip ring for conductivity. When changing the brush, first push the insulating handle to disengage the positioning pin from the positioning groove. Then rotate the insulating handle to align the positioning pin with the clearance groove. During this rotation, the push block moves the push rod, which then abuts against the brush and locks it in place. Afterward, the insulating handle can be pulled outward. During this pulling, the positioning pin abuts against the brush holder, pushing the brush holder outward.

[0009] Preferably, a positioning spring is installed on the insulated handle, with the positioning spring abutting against one side of the brush holder and the other side of the brush holder abutting against the positioning plate.

[0010] The positioning spring provides elastic force to position the brush holder, which is placed between the positioning plate and the positioning spring, ensuring stability and reliability.

[0011] Preferably, the outer wall of the top block is provided with an eccentrically positioned pushing surface, which contacts the top rod. The eccentrically positioned pushing surface ensures reliable pushing of the top rod.

[0012] Preferably, the brush holder has mounting holes, and the push rod is inserted into the mounting holes. A return spring is fitted onto the push rod, and the return spring abuts against the brush holder. Under the action of the return spring, the push rod is reliably supported on the top block, ensuring that the push rod is separated from the brush when the brush is working normally. The insertion of the push rod into the mounting holes ensures that the push rod and the brush holder move synchronously, thereby causing the brush and the brush holder to move synchronously.

[0013] Preferably, the base has a groove, and both sides of the groove opening have positioning protrusions. The brush holder has a sliding strip, which is fitted into the groove. The positioning protrusions cover the edge of the sliding strip and limit its movement. The sliding strip on the brush holder is fitted into the groove on the base and positioned by the positioning protrusions, allowing the sliding strip to move reliably within the groove.

[0014] Preferably, a displacement sensor is installed on the brush holder, and the displacement sensor is oriented toward the brush to detect the distance between the brush and the brush.

[0015] The displacement sensor monitors the distance between the brush and the sensor in real time. The more severe the brush wear, the larger the distance. When the distance exceeds the preset value, a brush replacement warning is issued so that the brush can be replaced in time.

[0016] Preferably, the end of the push rod is provided with locking teeth, and the brush surface is provided with corresponding saw teeth. When the push rod contacts the brush, the locking teeth and saw teeth cooperate to lock it.

[0017] When the push rod contacts the brush, the locking teeth and saw teeth work together to lock it in place, which improves the reliability of the connection between the brush and the push rod.

[0018] A method for replacing brushes while they are energized, comprising the following steps:

[0019] S1, rotate the insulating handle to make the top block push the top rod to move, the top rod abuts against the brush and locks the brush, at the same time the positioning column separates from the base, and the insulating handle unlocks from the base;

[0020] S2, pull the insulating handle outwards, the positioning post abuts against the brush holder, and pull the brush holder and brush outwards together;

[0021] S3, Disconnect the terminal block connected to the brush;

[0022] S4, rotate the insulating handle to separate the push rod from the brush;

[0023] S5, remove the old brush and replace it with a new one;

[0024] S6. After the new brush is installed in place, turn the insulating handle to make the top block push the top rod to move. The end of the top rod abuts against the brush to lock the brush.

[0025] S7, connect the terminal block to the new brush;

[0026] S8, push the insulating handle inward to push the brush holder and brush together toward the slip ring of the motor;

[0027] S9. After the brush holder is pushed into place, rotate the insulating handle to separate the top rod from the brush, and at the same time, the positioning post abuts against the base to limit the movement.

[0028] When replacing brushes while they are energized, the operation is performed by holding the insulated handle, ensuring safety and preventing electric shock. The brush holder is movable and mounted on the base. Pulling the brush outward using the insulated handle disengages it from the slip ring, providing ample operating space for brush replacement. Before pulling the brush holder outward, push the push rod to engage it with the brush, preventing the brush from being pushed by the constant-pressure spring and unable to disengage from the slip ring when the brush holder is pushed. This method of live brush replacement is convenient.

[0029] Preferably, a displacement sensor is installed on the brush holder to monitor the distance between the brush and the sensor in real time. The more severe the brush wear, the larger the distance. When the distance exceeds a preset value, a brush replacement warning is issued, ensuring that the brushes can be replaced in a timely manner.

[0030] Compared with the prior art, the beneficial effect of the present invention is that the brush can be replaced while energized. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of the present invention;

[0032] Figure 2 This is a schematic diagram of the structure from another direction of Embodiment 1 of the present invention;

[0033] Figure 3 This is a cross-sectional view of Embodiment 1 of the present invention;

[0034] Figure 4 This is a cross-sectional view of Embodiment 2 of the present invention;

[0035] Figure 5 This is a cross-sectional view of Embodiment 3 of the present invention.

[0036] In the diagram: 1. Insulated handle, 2. Top rod, 3. Base, 4. Brush holder, 5. Brush, 6. Constant pressure spring, 7. Support surface, 8. Brush grip, 9. Conductive ring of brush holder, 10. Top block, 11. Positioning post, 12. Pushing surface, 13. Mounting hole, 14. Return spring, 15. Protruding ring, 16. Anti-slip pad, 17. Slide groove, 18. Positioning protrusion, 19. Sliding bar, 20. Insertion hole, 21. Positioning plate, 22. Positioning groove, 23. Clearance groove, 2 4. Through slot; 25. Positioning spring; 26. Spring support plate; 27. Operating handle; 28. Displacement sensor; 29. ​​Locking tooth; 30. Sawtooth; 31. Slip ring; 32. Cylinder; 33. Drive piston; 34. Telescopic rod; 35. Preload spring; 36. Preload block; 37. Inflation chamber; 38. Inflation piston; 39. Push-pull rod; 40. Inflation pipe; 41. Return spring; 42. Exhaust valve; 43. One-way inlet valve; 44. One-way outlet valve. Detailed Implementation

[0037] The technical solution of the present invention will be further described in detail below through specific embodiments and in conjunction with the accompanying drawings:

[0038] Example 1: A device for replacing brushes while the circuit is energized (see attached document) Figure 1 Appendix Figure 2 Appendix Figure 3 The device includes an insulated handle 1, a top rod 2, and a base 3. A movable brush holder 4 is mounted on the base. A brush 5 and a constant-pressure spring 6 are mounted on the brush holder. The constant-pressure spring abuts against the brush, ensuring the brush end face is always in contact with the slip ring 31. The brush has an inclined support surface 7, and the constant-pressure spring has a spring ring supported on the support surface. A brush holder 8 is mounted on the brush holder, and both the brush and the constant-pressure spring are mounted on the brush holder. The base is securely connected to the brush holder conductive ring 9 on the motor.

[0039] An insulated handle is mounted on a base. The handle has a top block 10 and a positioning post 11. One end of the push rod is supported on the top block. The outer wall of the top block has an eccentrically positioned pushing surface 12 that contacts the push rod. The top block has an elliptical cross-section, forming four pushing surfaces around its circumference. The positioning post abuts against the base. Rotating the insulated handle causes the top block to push the push rod, which then abuts against the brush, separating the positioning post from the base. Pulling the insulated handle outward causes the positioning post to abut against the brush holder, pulling the brush holder and brush together outward.

[0040] The brush holder has mounting holes 13, and the push rod is inserted into the mounting holes. A return spring 14 is fitted onto the push rod, and the return spring abuts against the brush holder. One end of the push rod has a protruding ring 15, and the return spring abuts against the protruding ring. The other end of the push rod has an anti-slip pad 16, which abuts against the brush, increases friction, and makes the contact between the push rod and the brush more reliable.

[0041] The base has a sliding groove 17, and positioning protrusions 18 are provided on both sides of the opening of the sliding groove. The brush holder has a sliding strip 19, which is fitted into the sliding groove. The positioning protrusions cover the edge of the sliding strip to limit its movement. The brush holder has a socket 20, and the insulated handle is movably inserted into the socket. The socket is located on the sliding strip.

[0042] A positioning plate 21 is provided on the base, with a positioning groove 22 and a clearance groove 23. The clearance groove penetrates the positioning plate, and both the positioning groove and the clearance groove are adapted to the positioning post. The positioning post is placed in the positioning groove to position the insulating handle. The positioning post passes through the clearance groove and abuts against the brush holder, thereby pushing the brush holder to move. The positioning groove and the clearance groove are staggered. A through groove 24 is provided on the positioning plate for the push rod to pass through. During the outward pulling of the insulating handle, the push rod can pass through the through groove to avoid interference with the positioning plate. The through groove can be staggered from the clearance groove or coincide with the clearance groove. In this embodiment, the through groove and the clearance groove are staggered. A positioning spring 25 is installed on the insulating handle. The positioning spring abuts against one side of the brush holder, and the other side of the brush holder abuts against the positioning plate. One end of the sliding bar abuts against the positioning plate, and the other end of the sliding bar abuts against the positioning spring. The insulating handle is provided with a spring support plate 26, and the positioning spring abuts against the spring support plate. The end of the insulating handle is provided with an operating handle 27, which makes it more convenient to operate the insulating handle by holding the operating handle.

[0043] A method for replacing brushes while they are energized, comprising the following steps:

[0044] S1, push the insulating handle forward to disengage the positioning post from the positioning groove, then rotate the insulating handle to move the top block and push the top rod. The top rod abuts against the brush and locks the brush. At the same time, the positioning post separates from the base, and the insulating handle unlocks from the base. At this time, the positioning post is aligned with the clearance groove, and under the action of the positioning spring, the positioning post abuts against the sliding bar of the brush holder.

[0045] S2, pull the insulating handle outwards, the positioning pin abuts against the brush holder, and pull the brush holder and brush outwards together; the push rod passes through the through groove to avoid interference;

[0046] S3, Disconnect the terminal block connected to the brush;

[0047] S4, rotate the insulating handle to separate the push rod from the brush; under the action of the constant pressure spring, the brush is pushed outward;

[0048] S5, remove the old brush and replace it with a new one;

[0049] S6. After the new brush is installed in place, turn the insulating handle to make the top block push the top rod to move. The end of the top rod abuts against the brush to lock the brush.

[0050] S7, connect the terminal block to the new brush;

[0051] S8, push the insulating handle inward to push the brush holder and brush together toward the slip ring of the motor;

[0052] S9. After the brush holder is pushed into place, rotate the insulating handle to separate the top rod from the brush. At the same time, the positioning pin abuts against the base for limiting. At this time, the positioning pin is placed in the positioning groove on the positioning plate.

[0053] Example 2: A device for replacing brushes while the circuit is energized (see attached document) Figure 4 Its structure is similar to that of Embodiment 1, the main difference being that a displacement sensor 28 is installed on the brush holder in this embodiment. The displacement sensor is positioned facing the brush to detect the distance between the brush and the displacement sensor. A locking tooth 29 is provided at the end of the push rod, and serrations 30 are provided on the brush surface corresponding to the push rod. When the push rod contacts the brush, the locking tooth and the serrations engage to lock the brush. Other structures are the same as in Embodiment 1.

[0054] A method for replacing brushes while they are energized is similar in steps to that of Embodiment 1, with the main difference being that a displacement sensor is installed on the brush holder in this embodiment to monitor the distance between the brush and the sensor in real time. The more severe the brush wear, the larger the distance. When the distance exceeds a preset value, a brush replacement warning is issued. The signal detected by the displacement sensor is processed by a controller, which then controls the brush replacement warning operation. The brush replacement warning mainly includes indicator lights, alarm sounds, and other easily noticeable signals. When the operator detects the brush replacement warning, steps S1 to S9 are performed. After S9, the controller sets the preset value for the distance between the brush and the sensor.

[0055] Example 3: A device for replacing brushes while the circuit is energized (see appendix) Figure 5 Its structure is similar to that of Embodiment 2, with the main difference being that in this embodiment, a cylinder 32 is installed on the brush holder, a drive piston 33 is installed inside the cylinder, the drive piston is connected to a telescopic rod 34, a pre-tension spring 35 is connected to the end of the telescopic rod, a pre-tension block 36 is connected to the pre-tension spring, and the pre-tension block is positioned facing the brush end face; an inflation chamber 37 is provided inside the insulating handle, an inflation piston 38 is installed inside the inflation chamber, the inflation piston is connected to a push-pull rod 39, the push-pull rod extends out of the insulating handle, and an inflation pipe 40 is connected between the cylinder and the mounting chamber. A return spring 41 is installed inside the cylinder, and the return spring abuts against the drive piston. An exhaust pipe is connected to the cylinder, and an exhaust valve 42 is installed on the exhaust pipe. The inflation chamber is connected to an inlet pipe and an outlet pipe, a one-way inlet valve 43 is installed on the inlet pipe, a one-way outlet valve 44 is installed on the outlet pipe, and the inflation pipe is connected to the outlet pipe.

[0056] Before the brush needs to be replaced after a period of use, the force exerted by the constant pressure spring on the brush decreases due to brush wear. The cylinder is inflated by pushing and pulling the push-pull rod, which pushes the telescopic rod outwards. The preload block abuts against the brush, increasing the force on the brush and the contact force between the brush and the slip ring, allowing the brush to continue to be used for a period of time, thus making full use of the brush. This method can be used as an emergency measure when the brush needs to be replaced but no replacement brush is available. During brush removal and replacement, in step S5, the cylinder is inflated by pushing and pulling the push-pull rod, causing the telescopic rod to extend outwards and press against the brush, facilitating the removal of the brush from the brush holder. The exhaust valve is opened to release air from the cylinder, allowing the telescopic rod to return to its original position. After the return is complete, the exhaust valve is closed. The other structures of the device for replacing brushes while they are energized, and the other steps of the method for replacing brushes while they are energized, are the same as in Example 2.

[0057] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Other variations and modifications may be made without departing from the technical solutions described in the claims.

Claims

1. A device for replacing brushes while the circuit is energized, characterized in that, The system includes an insulated handle, a push rod, and a base. A movable brush holder is mounted on the base, and brushes are installed on the brush holder. The insulated handle is mounted on the base and has a top block and a positioning post. One end of the push rod is supported on the top block, and the positioning post abuts against the base. Rotating the insulated handle causes the top block to push the push rod, which then abuts against the brush, separating the positioning post from the base. Pulling the insulated handle outward causes the positioning post to abut against the brush holder, pulling the brush holder and brushes outward together. A cylinder is mounted on the brush holder. An internal drive piston is installed, which is connected to a telescopic rod. A pre-tension spring is connected to the end of the telescopic rod, and a pre-tension block is connected to the pre-tension spring, with the pre-tension block facing the brush end face. An air chamber is provided inside the insulated handle, and an air-inflating piston is installed inside the air chamber. The air-inflating piston is connected to a push-pull rod, and an air-inflating pipe is connected between the cylinder and the air-inflating chamber. Pushing and pulling the push-pull rod inflates the cylinder, thereby pushing the telescopic rod outward. The pre-tension block abuts against the brush, thereby increasing the force on the brush and increasing the contact force between the brush and the slip ring.

2. The device for replacing brushes while the circuit is energized, as described in claim 1, is characterized in that... The base is equipped with a positioning plate, which has a positioning groove and a clearance groove. The clearance groove passes through the positioning plate and is adapted to the positioning post. The positioning post is placed in the positioning groove to position the insulated handle. The positioning post passes through the clearance groove and abuts against the brush holder, thereby pushing the brush holder to move.

3. The device for replacing brushes while the circuit is energized, as described in claim 2, is characterized in that... A positioning spring is installed on the insulated handle. The positioning spring abuts against one side of the brush holder, and the other side of the brush holder abuts against the positioning plate.

4. The device for replacing brushes while the circuit is energized, as described in claim 1, is characterized in that... The outer wall of the top block is provided with an eccentrically set pushing surface, which contacts the top rod.

5. The device for replacing brushes while the circuit is energized, as described in claim 1, is characterized in that... The brush holder has mounting holes, and the push rod is inserted into the mounting holes. A return spring is fitted on the push rod, and the return spring abuts against the brush holder.

6. The device for replacing brushes while the circuit is energized, as described in claim 1, is characterized in that... The base is provided with a sliding groove, and positioning protrusions are provided on both sides of the opening of the sliding groove. The brush holder is provided with a sliding strip, which is fitted into the sliding groove. The positioning protrusions cover the edge of the sliding strip to limit the sliding strip.

7. A device for replacing brushes under energized conditions according to any one of claims 1 to 6, characterized in that, A displacement sensor is installed on the brush holder, and the displacement sensor is oriented toward the brush to detect the distance between the brush and the brush.

8. A device for replacing brushes under energized conditions according to any one of claims 1 to 6, characterized in that, The end of the push rod is provided with locking teeth, and the brush surface is provided with corresponding serrations. When the push rod contacts the brush, the locking teeth and serrations cooperate to lock it.

9. A method for replacing brushes while they are energized, characterized in that, The method of replacing brushes using the energized brush replacement device according to any one of claims 1 to 8 includes the following steps: S1, rotate the insulating handle to make the top block push the top rod to move, the top rod abuts against the brush and locks the brush, at the same time the positioning column separates from the base, and the insulating handle unlocks from the base; S2, pull the insulating handle outwards, the positioning pin abuts against the brush holder, and pull the brush holder and brush outwards together; S3, Disconnect the terminal block connected to the brush; S4, rotate the insulating handle to separate the push rod from the brush; S5, remove the old brush and replace it with a new one; S6. After the new brush is installed in place, turn the insulating handle to make the top block push the top rod to move. The end of the top rod abuts against the brush to lock the brush. S7, connect the terminal block to the new brush; S8, push the insulating handle inward to push the brush holder and brush together toward the slip ring of the motor; S9. After the brush holder is pushed into place, rotate the insulating handle to separate the top rod from the brush, and at the same time, the positioning post abuts against the base to limit the movement.

10. The method for replacing brushes under energized conditions according to claim 9, characterized in that, A displacement sensor is installed on the brush holder to monitor the distance between the brush and the sensor in real time. The more severe the brush wear, the larger the distance. When the distance exceeds the preset value, a brush replacement warning is issued.

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