A carbon brush wear reminder device for a carbon brush motor used for cross-connected power transmission

Abstract

The present invention discloses a carbon brush wear warning device for a carbon brush motor for cross-connected power transmission, which relates to the technical field of carbon brush motors. The device comprises a housing and a motor rotor disposed in the housing, and a collector ring disposed on the motor rotor. The collector ring is provided with a carbon brush mounting bracket, the carbon brush mounting bracket is provided with a carbon brush, and the carbon brush mounting bracket is provided with an auxiliary pressure assembly and a multi-stage warning assembly; the auxiliary pressure assembly is provided on the outside of the carbon brush mounting bracket, and the multi-stage warning assembly is provided on the outside of the carbon brush mounting bracket. The present invention sets a multi-stage warning assembly, presses a push switch through a trigger plate in a trigger mechanism, and judges the degree of wear of the carbon brush through the different colors of light displayed by the warning light, and replaces the carbon brush in a timely manner. The trigger condition is a simple mechanical trigger, which avoids the use of high-precision products such as compact sensors. The dust generated by carbon brush wear will not affect the trigger condition, and the warning trigger has high stability.

Description

Technical Field

[0001] The invention relates to the technical field of carbon brush motors, in particular to a carbon brush wear prompting device for a carbon brush motor used for cross-connection power transmission. Background Art

[0002] Brushless motors are a common type of motor, widely used in various industrial and consumer applications. They operate by transmitting electrical energy to the rotating rotor via carbon brushes and a commutator (or slip rings). Silicone cables are used to transmit electrical energy from the power supply to the fixed components of the brushless motor (such as the motor's terminals or brush holder). Silicone cables offer excellent insulation and high-temperature resistance, making them suitable for withstanding the high voltages and currents encountered during motor operation. As the motor rotates, carbon brushes transmit electrical energy to the coils via the commutator. Because they are primarily composed of carbon, they are susceptible to wear and require regular maintenance and replacement, as well as cleaning of carbon deposits.

[0003] Current carbon brush wear monitoring technologies mainly rely on the following two solutions, but they still have significant limitations:

[0004] ‌1. Traditional mechanical trigger monitoring‌

[0005] Basic Principle: Alarms are generated through physical contact or spring deformation triggered by carbon brush wear. For example, conductive probes or linked micro switches are embedded in the tail end of the carbon brush. This method only supports single-level alarms and cannot quantify the degree of wear or predict the remaining life. Mechanical contacts are susceptible to oxidation and dust contamination, requiring frequent calibration of contact sensitivity.

[0006] 2. Electronic sensor monitoring technology

[0007] Resistance sensing: indirectly assesses wear by measuring changes in carbon brush resistance, but is susceptible to interference from contact resistance fluctuations.

[0008] Optical sensing: Fiber Bragg grating (FBG) is used to measure the axial length change of the carbon brush, but the internal structure of the carbon brush needs to be modified;

[0009] Electronic sensor monitoring has high requirements for the environment. The dust generated by carbon brush wear will affect these high-precision sensors, resulting in unstable measurement results.

[0010] To sum up, the following problems exist:

[0011] The reliability of electronic components decreases in high electromagnetic interference, high temperature (200°C), and dusty environments;

[0012] Multi-sensor fusion solutions are expensive and difficult to adapt to standardized carbon brush sizes;

[0013] Existing devices mostly rely on manual regular inspections or single-point threshold alarms, which cannot achieve dynamic analysis of wear rate and preventive maintenance planning.

[0014] Therefore, the present application proposes a carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission to solve the above problems. Summary of the Invention

[0015] The object of the present invention is to provide a carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission, so as to solve the problems raised in the above background technology.

[0016] To achieve the above objectives, the present invention provides the following technical solutions: a carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission, comprising a housing and a motor rotor disposed within the housing, and a slip ring disposed on the motor rotor, the slip ring being provided with a carbon brush mounting bracket, the carbon brush being provided on the carbon brush mounting bracket, and the carbon brush being provided on the carbon brush mounting bracket, the carbon brush being provided on the carbon brush mounting bracket, and an auxiliary pressure assembly and a multi-stage reminder assembly being provided on the carbon brush mounting bracket;

[0017] The auxiliary pressure component is arranged on the outside of the carbon brush mounting frame and is used to assist in squeezing the carbon brush;

[0018] The multi-stage prompting component is arranged on the outside of the carbon brush mounting bracket and is linked with the auxiliary pressure component to warn of the degree of wear of the carbon brush.

[0019] Preferably, the carbon brush mounting bracket includes a bracket fixedly mounted on the end cover of the housing, the other end of the bracket is fixedly connected to a mounting ring, the surface of the mounting ring is fixedly mounted with a mounting seat by bolts, the carbon brush is inserted into the mounting seat, the inner wall of the mounting seat is slidably connected to a push plate, the push plate is arranged between the carbon brush and the mounting seat, the opposite surfaces of the push plate and the mounting seat are both provided with connecting columns, and a compression spring is sleeved on the connecting column.

[0020] Preferably, the auxiliary pressure assembly includes a travel groove opened on the surface of the mounting seat, a pressure rod is rotatably connected in the travel groove, a slot is opened at one end of the pressure rod extending into the mounting seat, and an insertion rod is slidably connected in the slot, an extrusion spring is arranged between the insertion rod and the slot, the end of the insertion rod is rotatably connected to a roller, and an auxiliary spring is arranged between the other end of the pressure rod and the mounting seat.

[0021] Preferably, one end of the travel groove close to the inner side of the mounting seat is trumpet-shaped, and the pressure rod is an L-shaped structure, and the surfaces of the pressure rod and the mounting seat are both provided with protrusions for connecting to the auxiliary spring.

[0022] Preferably, the multi-stage prompt assembly includes a warning light fixedly mounted on the surface of the mounting ring, a push switch fixedly mounted on the inner side of the mounting seat, and a trigger mechanism arranged on the inner side of the pressure rod, and the push switch is electrically connected to the warning light.

[0023] Preferably, the trigger mechanism includes a triangular box fixedly mounted on the inner side of the pressure rod, the inner wall of the triangular box is rotatably connected to a trigger plate, and a buffer spring is fixedly connected between the other end of the trigger plate and the inner wall of the triangular box.

[0024] Preferably, three push switches are provided in the same mounting base, and the warning light is provided with a three-color light display, and the three push switches correspond to the three-color light display.

[0025] Preferably, a through hole is provided at the top of the mounting seat for the carbon brush connecting wire to pass through.

[0026] Preferably, cover plates are fixedly mounted on both sides of the mounting ring, and the inner ring surface of the cover plate is provided with a sealing bearing, and the inner ring surface of the sealing bearing is fixedly connected to the shaft of the motor rotor.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] 1. Multi-level prompts and early warnings

[0029] This application achieves more accurate and early wear prompts by setting up a multi-level prompt component in conjunction with an auxiliary pressure component. The press switch in the multi-level prompt component can be triggered in sequence according to the degree of wear of the carbon brush. The different colors of light displayed by the warning light (such as green, yellow, and red) can intuitively reflect the wear status of the carbon brush, so that users can know in advance which carbon brushes are about to reach the end of their service life, which is convenient for timely stocking and replacement.

[0030] 2. Make up for the lack of spring thrust

[0031] During the use of the carbon brush, as the carbon brush wears, the spring that pushes the carbon brush close to the collector ring will gradually stretch, causing its thrust to gradually weaken. This insufficient thrust may lead to poor contact between the carbon brush and the collector ring, thereby affecting the normal operation of the motor. The auxiliary pressure assembly in this application effectively makes up for this deficiency. When the carbon brush wears and causes the spring thrust to weaken, the roller in the auxiliary pressure assembly can be driven by the auxiliary spring and, through the transmission of the pressure rod, apply additional pressure to the carbon brush, ensuring that the carbon brush always maintains close contact with the collector ring, thereby avoiding poor conductivity caused by poor contact.

[0032] 3. Improve stability and reliability

[0033] Traditional carbon brush wear indicator devices often rely on complex electronic sensors or mechanical contacts. These components are prone to failure in harsh environments such as high electromagnetic interference, high temperatures, and dust, resulting in inaccurate or malfunctioning indicators. However, this application uses a simple mechanical triggering method, with a multi-stage indicator assembly and auxiliary pressure assembly, to achieve stable and reliable wear indication. The dust generated by carbon brush wear does not affect the triggering conditions, so the device in this application can maintain stable performance in a variety of harsh environments.

[0034] In summary, the present invention, by providing a multi-stage prompt component in conjunction with an auxiliary pressure component, not only compensates for the problem of insufficient thrust caused by the carbon brush's own spring thrust as the spring extends, but also achieves multi-stage prompts by sequentially triggering the press switch through the trigger mechanism on the pressure rod. This design allows users to understand the degree of wear of the carbon brush in advance and prepare replacements in advance, thereby ensuring the normal operation of the motor and extending the service life of the equipment. At the same time, the device of the present application also has the advantages of simple structure, stability and reliability, and strong adaptability, and has high practical value and promotion prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 This is an overall exploded structural view of the present invention;

[0036] Figure 2 This is a schematic diagram of the three-dimensional structure of the mounting ring of the present invention;

[0037] Figure 3 This is a schematic diagram of the three-dimensional structure of the mounting base and carbon brush of the present invention;

[0038] Figure 4 This is a schematic diagram of the front view structure of the mounting base of the present invention;

[0039] Figure 5 for Figure 4 Schematic diagram of the cross-section structure at point A in the middle;

[0040] Figure 6 It is a schematic diagram of the three-dimensional structure of the push plate of the present invention;

[0041] Figure 7 This is a schematic diagram of the internal structure of the mounting base of the present invention;

[0042] Figure 8 It is a schematic diagram of the overall structure of the present invention;

[0043] Figure 9 This is a schematic diagram of the front cross-section structure of the triangular box of the present invention;

[0044] Figure 10 This is a schematic diagram of the stroke structure of the pressure rod when the carbon brush of the present invention is worn;

[0045] Figure 11 for Figure 10 Enlarged structural diagram at point B in the middle.

[0046] Among them, 1. Shell; 2. Motor rotor; 3. Collector ring; 4. Carbon brush mounting bracket; 401. Bracket; 402. Mounting ring; 403. Mounting seat; 404. Push plate; 405. Connecting column; 406. Compression spring; 5. Carbon brush; 6. Auxiliary pressure assembly; 601. Travel groove; 602. Pressure rod; 603. Roller; 604. Auxiliary spring; 605. Insert rod; 606. Extrusion spring; 7. Multi-level prompt assembly; 701. Warning light; 702. Press switch; 8. Through hole; 9. Cover plate; 10. Sealed bearing; 11. Trigger mechanism; 1101. Triangle box; 1102. Trigger plate; 1103. Buffer spring. DETAILED DESCRIPTION

[0047] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0048] See also Figures 1 to 11 The present invention provides a technical solution: a carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission, comprising a housing 1 and a motor rotor 2 arranged in the housing 1, and a slip ring 3 arranged on the motor rotor 2, a carbon brush mounting bracket 4 being provided on the slip ring 3, a carbon brush 5 being provided on the carbon brush mounting bracket 4, and an auxiliary pressure component 6 and a multi-stage reminder component 7 being provided on the carbon brush mounting bracket 4.

[0049] Specifically, such as Figure 1 、 Figure 2 、 Figure 5 and Figure 7As shown, the carbon brush mounting bracket 4 includes a bracket 401 fixedly mounted on the end cover of the housing 1, and the other end of the bracket 401 is fixedly connected to a mounting ring 402, which is sleeved on the outer ring of the collector ring 3. The surface of the mounting ring 402 is fixedly mounted with a mounting seat 403 by bolts, and the mounting ring 402 is provided with a plug hole corresponding to the mounting seat 403. Cover plates 9 are fixedly mounted on both sides of the mounting ring 402, and the inner ring surface of the cover plate 9 is provided with a sealing bearing 10. The inner ring surface of the sealing bearing 10 is fixedly connected to the shaft of the motor rotor 2. The cover plate 9 is used to seal the mounting ring 402 and the collector ring 3 to avoid carbon powder splashing after the carbon brush 5 is worn. The carbon brush 5 is inserted into the mounting Inside the seat 403, the carbon brush 5 is in contact with the collector ring 3, and the inner wall of the mounting seat 403 is slidably connected with a push plate 404, which is arranged between the carbon brush 5 and the mounting seat 403. The push plate 404 and the opposite surfaces of the mounting seat 403 are provided with connecting columns 405, and the connecting columns 405 are provided with compression springs 406. There are four compression springs 406, which are respectively provided at the four corners of the mounting seat 403, and are used to push the push plate 404 to move, thereby driving the carbon brush 5 to move. When the carbon brush 5 is worn, the carbon brush 5 can always be close to the collector ring 3. A through hole 8 is provided at the top of the mounting seat 403 for the carbon brush 5 connecting wire to pass through, and the wire connected to the other end of the carbon brush 5 is led out through the through hole 8.

[0050] The auxiliary pressure assembly 6 is arranged on the outside of the carbon brush mounting bracket 4 and is used for assisting in squeezing the carbon brush 5 .

[0051] Specifically, such as Figure 5 、 Figure 9 、 Figure 10 and Figure 11As shown, the auxiliary pressure assembly 6 includes a travel groove 601 provided on the surface of the mounting seat 403, a pressure rod 602 is rotatably connected in the travel groove 601, a slot is provided at one end of the pressure rod 602 extending into the mounting seat 403, and an insertion rod 605 is slidably connected in the slot, an extrusion spring 606 is provided between the insertion rod 605 and the slot, and a roller 603 is rotatably connected to the end of the insertion rod 605. When the carbon brush 5 is not worn or the wear is not serious, the roller 603 rolls close to the side of the carbon brush 5. An auxiliary spring 604 is provided between the other end of the pressure rod 602 and the mounting seat 403. The end of the travel groove 601 close to the inner side of the mounting seat 403 is trumpet-shaped, and the pressure rod 602 It is an L-shaped structure, and the surfaces of the pressure rod 602 and the mounting seat 403 are both provided with bumps for connecting to the auxiliary spring 604. When the carbon brush 5 is worn to a certain extent, when the push plate 404 is under the roller 603, the roller 603 drives the insertion rod 605 to move through the extrusion spring 606, so that the roller 603 moves to the top of the push plate 404. As the carbon brush 5 continues to wear, the compression spring 406 that pushes the push plate 404 to move changes due to the change in compression amount, and the thrust provided by the auxiliary spring 604 drives the roller 603 to squeeze the push plate 404 through the pressure rod 602, thereby compensating for the weakness of the compression spring 406 and allowing the carbon brush 5 to stably adhere to the collector ring 3.

[0052] The multi-level prompting assembly 7 is arranged on the outside of the carbon brush mounting bracket 4 and is linked with the auxiliary pressure assembly 6 to warn of the degree of wear of the carbon brush 5 .

[0053] Specifically, such as Figure 1 、 Figure 6 、 Figure 10 and Figure 11As shown, the multi-level prompt component 7 includes a warning light 701 fixedly mounted on the surface of the mounting ring 402, a push switch 702 fixedly mounted on the inner side of the mounting seat 403, and a trigger mechanism 11 arranged on the inner side of the pressure rod 602, the push switch 702 is electrically connected to the warning light 701, wherein the trigger mechanism 11 includes a triangular box 1101 fixedly mounted on the inner side of the pressure rod 602, the inner wall of the triangular box 1101 is rotatably connected to the trigger plate 1102, and a buffer spring 1103 is fixedly connected between the other end of the trigger plate 1102 and the inner wall of the triangular box 1101, and three push switches 702 are provided in the same mounting seat 403, and the warning light 701 is provided. A three-color light display is provided, and the three push switches 702 correspond to the three-color light display. It should be noted that the three-color lights are green, yellow and red, which correspond to the three push switches 702 in sequence. Green indicates that the carbon brush 5 is worn out by more than half, yellow indicates that the carbon brush 5 is worn out by more than two-thirds, and red indicates that the carbon brush 5 is worn out to the limit and needs to be replaced immediately. As the carbon brush 5 wears, the angle of the pressure rod 602 changes accordingly, and the pressure rod 602 gradually approaches the push switch 702, thereby driving the trigger plate 1102 to first trigger the push switch 702 on the lower side, then trigger the push switch 702 in the middle, and finally trigger the push switch 702 on the upper side, thereby achieving the purpose of multi-level prompts.

[0054] Working principle: During installation, the mounting ring 402 is fixed to the outer ring of the collector ring 3 through the bracket 401, and the two ends of the mounting ring 402 are sealed with the cover plate 9. The new carbon brush 5 is inserted into the mounting seat 403, and the carbon brush 5 is squeezed to the limit so that the roller 603 is close to the side of the carbon brush 5. The mounting seat 403 is installed on the mounting ring 402 by bolts. When the carbon brush 5 is worn, the compression spring 406 drives the push plate 404 to push the carbon brush 5 along the inner wall of the mounting seat 403 so that the carbon brush 5 is close to the collector ring 3. When the carbon brush 5 is worn by more than half, the push plate 404 moves to the bottom of the roller 603. At this time, the roller 603 Under the action of the auxiliary spring 604, the pressure rod 602 moves to the top of the push plate 404. As the carbon brush 5 wears, the angle of the pressure rod 602 also changes, thereby driving the trigger plate 1102 on the trigger mechanism 11 to squeeze the press switch 702 in turn, thereby triggering the warning light 701. Green indicates that the carbon brush 5 is worn more than half, yellow indicates that the carbon brush 5 is worn more than two-thirds, and red indicates that the carbon brush 5 is worn to the limit. In the process of the roller 603 moving on the top of the push plate 404, it can continuously apply a thrust to the push plate 404 to compensate for the thrust released by the compression spring 406, so that the carbon brush 5 is always close to the collector ring 3.

[0055] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission, comprising a housing, a motor rotor disposed within the housing, and a slip ring disposed on the motor rotor, a carbon brush mounting bracket disposed on the slip ring, and a carbon brush disposed on the carbon brush mounting bracket, characterized in that: The carbon brush mounting bracket is provided with an auxiliary pressure component and a multi-stage prompt component; The carbon brush mounting bracket includes a bracket fixedly mounted on the end cover of the housing, the other end of the bracket is fixedly connected to a mounting ring, the surface of the mounting ring is fixedly mounted with a mounting seat by bolts, the carbon brush is inserted into the mounting seat, the inner wall of the mounting seat is slidably connected to a push plate, the push plate is arranged between the carbon brush and the mounting seat, and the opposing surfaces of the push plate and the mounting seat are both provided with connecting columns, and a compression spring is sleeved on the connecting column; The auxiliary pressure component is arranged on the outside of the carbon brush mounting frame and is used for auxiliary squeezing of the carbon brush; The auxiliary pressure assembly includes a travel groove provided on the surface of the mounting seat, a pressure rod rotatably connected in the travel groove, a slot provided at one end of the pressure rod extending into the mounting seat, an insertion rod slidably connected in the slot, an extrusion spring provided between the insertion rod and the slot, a roller rotatably connected to the end of the insertion rod, and an auxiliary spring provided between the other end of the pressure rod and the mounting seat; The multi-level prompt component is set on the outside of the carbon brush mounting bracket and is linked with the auxiliary pressure component to warn the wear degree of the carbon brush; The multi-level prompt assembly includes a warning light fixedly mounted on the surface of the mounting ring, a push switch fixedly mounted on the inner side of the mounting seat, and a trigger mechanism arranged on the inner side of the pressure rod. The push switch is electrically connected to the warning light. The trigger mechanism includes a triangular box fixedly mounted on the inner side of the pressure rod. The inner wall of the triangular box is rotatably connected to a trigger plate. A buffer spring is fixedly connected between the other end of the trigger plate and the inner wall of the triangular box. Three push switches are provided in the same mounting seat, and the warning light is provided with a three-color light display. The three push switches correspond to the three-color light display.

2. The carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission according to claim 1, characterized in that: One end of the travel groove close to the inner side of the mounting seat is in a trumpet shape, and the pressure rod has an L-shaped structure.

3. The carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission according to claim 2, characterized in that: The surfaces of the pressure rod and the mounting seat are both provided with protrusions for connecting with the auxiliary spring.

4. The carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission according to claim 1, characterized in that: A through hole for the carbon brush connecting wire to pass through is provided on the top of the mounting seat.

5. The carbon brush wear reminder device for a carbon brush motor for cross-connected power transmission according to claim 1, characterized in that: Cover plates are fixedly mounted on both sides of the mounting ring. The inner ring surface of the cover plate is provided with a sealing bearing. The inner ring surface of the sealing bearing is fixedly connected to the shaft of the motor rotor.

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