Brush plate system and vehicle motor assembly

Abstract

The utility model relates to a brush plate system and vehicle motor assembly. The brush plate system comprises a brush plate, brushes and a brush arm, the brush arm extends in a direction transverse to the longitudinal axis of the brush, one end of the brush arm is fixed to the brush plate, and the other end is fixed to the end of the brush away from the center of the brush plate, and a damping member, the damping member is installed on the brush plate and abuts against the brush arm from outside. The vehicle motor assembly comprises the brush plate system as described above. The brush plate system according to the utility model can reduce the noise generated during the operation of the motor.

Description

Technical Field

[0001] This invention relates to the field of electric motors. Specifically, in a first aspect, it relates to a brush plate system for a vehicle motor. In a second aspect, it relates to a vehicle motor assembly including the brush plate system, such as an anti-pinch motor for window adjustment. Background Technology

[0002] Figure 1 A typical vehicle motor assembly 1 is shown, including a motor housing 10, a gearbox assembly 20, and a motor (not shown). Motor components (such as the armature, commutator, and motor shaft 80) are assembled in the motor housing 10, wherein one end of the motor shaft 80 is supported within the motor housing 10, and the other end extends into the gearbox assembly 20 to transmit the rotational motion of the armature (not shown) to a transmission mechanism (also not shown) within the gearbox assembly 20.

[0003] To control the operation of the motor, the vehicle motor assembly 1 also includes a circuit board 30 and a circuit board cover 40 for protecting the circuit board 30. See also... Figure 2 The circuit board 30 is equipped with two Hall sensors 50 (each with a single output pin) and two corresponding capacitors 60 to meet EMC requirements, and may also contain other components such as resistors. Furthermore, three through holes 31 are provided on the circuit board 30 to allow screws to pass through and be screwed into the threaded holes 21 of the gearbox assembly 20 for mounting the circuit board 30 to the gearbox assembly 20. This arrangement requires an additional circuit board 30 and a corresponding circuit board cover 40, and the Hall sensors 50 and capacitors 60 need to be soldered to the circuit board 30. Additionally, the circuit board 30 needs to be placed inside the gearbox assembly 20, and the circuit board cover 40 needs to be ultrasonically soldered to the gearbox assembly 20, resulting in increased size and manufacturing cost of the vehicle motor assembly.

[0004] Most vehicle motor assemblies 1 used for window adjustment currently employ brushed motors, which include a brush plate system 70 (see detailed structure for more information). Figure 3 The brush plate system 70 is assembled within the gearbox assembly 20 and mates with the motor housing 10. For example, a seal may be provided between the mating end faces of the brush plate system 70 and the motor housing 10.

[0005] like Figure 3 As shown, the brush plate system 70 includes a brush plate 71, a brush tube 72, a brush 73, an inductor 74, and an electrical connector 75. The brush tube 72 is fixed to the upper side of the brush plate 71, and the brush 73 is slidably arranged inside the brush tube 72. For ease of manufacturing, the brush tube 72 is generally formed by brush holes formed therein during the injection molding of the brush plate. The inductor 74 is mounted on the upper side of the brush plate 71 and includes two inductor leads (…). Figure 3Only one is shown in the image), and a terminal leg (located on the upper side of the brush plate 71, see [link]). Figure 3 One terminal is electrically connected to the corresponding brush 73, and the other terminal (not shown, located on the underside of the brush plate 71) is electrically connected to the corresponding pin (not shown) of the socket 75.

[0006] The brush plate system 70 will be positioned in the gearbox assembly 20 of the motor assembly 1 on the upper side, where the brush tube 73 and inductor 74 are installed, and on the opposite side, the lower side, it will be positioned in the motor cover 20.

[0007] To position the brush 73, a torsion spring 76 is used to allow the brush 73 to slide back and forth within the brush tube 72. For example... Figure 3A As shown, the torsion spring 76 is sleeved on the positioning post provided on the brush plate 71. It includes two spring legs. One spring leg is positioned against the brush plate 71, and the other spring leg is against the end of the brush 73 away from the center of the brush plate to apply pressure toward the center of the brush plate.

[0008] In this design, because the brush 73 is not fixed and there is a gap between it and the brush tube 72, the brush 73 will tilt significantly when sliding back and forth within the brush tube 72 during motor operation, causing vibration (see...). Figure 3B This leads to the generation of high-frequency noise.

[0009] The goal is to provide a brush plate system and corresponding vehicle motor components that overcome the above-mentioned shortcomings. Utility Model Content

[0010] On one hand, the present invention provides a brush plate system, including a brush plate and a brush and a brush arm, the brush arm extending in a direction transverse to the longitudinal axis of the brush, one end of the brush arm being fixed to the brush plate and the other end being fixed to the end of the brush away from the center of the brush plate; and a damping member, the damping member being mounted on the brush plate and abutting against the brush arm from the outside.

[0011] The brush plate system design of this utility model eliminates the gap between the brush arm and the brush, allowing for secure brush positioning. Simultaneously, the damping component absorbs the high-frequency vibrations generated by the brush during motor operation, thereby reducing noise.

[0012] According to an embodiment, the brush arm is a leaf spring structure, with the plate plane transverse to the longitudinal axis of the brush. The material of the leaf spring is, for example, a copper-beryllium alloy.

[0013] According to an embodiment, the brush plate system further includes a retaining plate and a fixed support portion, which are arranged on the brush plate at 90-degree intervals from the brushes along the circumferential direction of the brush plate. A leaf spring is fixed to the retaining plate, for example by riveting. The fixed support portion has a slot for the retaining plate to be inserted. The retaining plate is made of, for example, brass. The fixed support portion is made of, for example, PA6+GF30, and can be integrally formed with the brush plate during injection molding.

[0014] According to an embodiment, the leaf spring comprises three sections. The first section extends perpendicular to the longitudinal axis of the brush, and its plane is also perpendicular to the longitudinal axis of the brush. The second section is fixed to a retaining plate. The third section is a curved transition section located between the first and second sections. Due to the structure of the leaf spring, it can elastically deform in the longitudinal direction of the brush, but not in the direction transverse to the longitudinal direction of the brush. This allows the brush to move along its longitudinal direction, but not in the direction transverse to its longitudinal direction.

[0015] According to an embodiment, the first segment includes a first part fixed to the brush and a second part forming an obtuse angle with the first part. A damping member abuts against the second part. In the uninstalled state, the second part forms an acute angle with the second segment, for example, 80 degrees. In the installed state, a leaf spring applies a biasing force to the brush, wherein the first part is perpendicular to the second segment, and the second part forms an obtuse angle with the second segment, for example, 104 degrees, 105 degrees, 106 degrees, 107 degrees, and 111 degrees.

[0016] According to the embodiment, the third segment is provided with reinforcing ribs to improve the strength of the third segment.

[0017] According to an embodiment, the leaf spring and the brush are fixed to each other by a snap-fit ​​mechanism. Specifically, the snap-fit ​​end of the leaf spring is U-shaped, with protrusions on all four sides, and the corresponding snap-fit ​​end of the brush is a square-column protrusion. Preferably, the protrusions are slightly inclined towards the center to facilitate locking the brush.

[0018] According to an embodiment, the brush plate has an upper side and an opposite lower side. The brush plate system also integrates circuit elements such as Hall sensors and capacitors, which are positioned on the upper side of the brush plate (e.g., the side facing the gearbox assembly of the motor assembly), while the brush and leaf spring assembly are positioned on the lower side of the brush plate (e.g., the side facing the motor). This design eliminates the need for circuit boards and corresponding circuit board covers, as well as the steps of assembling the circuit boards and circuit board covers and ultrasonically soldering them.

[0019] According to embodiments, the Hall sensor and capacitor can be separate components or integrated into a single component. Preferably, a Hall sensor with two output pins is provided, thereby eliminating the need for a Hall sensor with a single output pin and a corresponding capacitor, while still meeting EMC requirements.

[0020] According to the embodiment, both the Hall sensor and the capacitor are soldered to corresponding connection terminals on the brush plate. For example, the upper side of the brush plate is provided with a positioning pin for connecting the pins of the Hall sensor, the positioning pin having a positioning groove for placing the pins, and the two pins of the capacitor are also connected to corresponding pins of the Hall sensor, such as the positive and negative power supply pins.

[0021] On the other hand, this utility model provides a vehicle motor assembly, which includes the brush plate system described above, a motor housing, a motor mounted in the motor housing, and a gearbox assembly. The brush plate system is assembled between the gearbox assembly and the motor housing, with one end of the motor shaft supported inside the motor housing and the other end extending through the brush plate system into the gearbox assembly.

[0022] The brush plate system and vehicle motor assembly of this utility model have the following advantages. First, compared with... Figure 3 Compared to existing brush plate system designs, the brush plate system of this invention can reduce the noise generated during motor operation, for example, by 2 dB. Secondly, since Hall sensors and capacitors can be integrated into the brush plate system, there is no need for additional protective circuit boards and circuit board covers, as well as corresponding assembly and ultrasonic welding steps, thereby reducing the size and manufacturing cost of the vehicle motor components. Attached Figure Description

[0023] The embodiments of the present invention will be explained in more detail in the accompanying drawings, wherein:

[0024] Figure 1 This is a schematic exploded perspective view of an example of a prior art window motor assembly;

[0025] Figure 2 yes Figure 1 A schematic enlarged view of the circled portion;

[0026] Figure 3 yes Figure 1 A schematic perspective view of the brush plate system in a motor assembly;

[0027] Figure 3A yes Figure 3 A schematic enlarged view of the circled portion;

[0028] Figure 3B yes Figure 3A A schematic enlarged view of the circled portion;

[0029] Figure 4 This is a schematic exploded perspective view of an example of a car window motor assembly according to an embodiment of the present utility model;

[0030] Figure 5 This is a schematic perspective view of the brush plate system according to an embodiment of the present invention, viewed from the top side of the brush plate.

[0031] Figure 5A yes Figure 5 A schematic diagram of the Hall sensor in the image;

[0032] Figure 5B yes Figure 5 A schematic diagram of the capacitor in the diagram;

[0033] Figure 6 yes Figure 5 A schematic perspective view of the brush plate system from below the brush plate;

[0034] Figure 7 yes Figure 6 A schematic perspective view of the leaf spring in its installed state;

[0035] Figure 8A yes Figure 7 Another schematic perspective view of the leaf spring;

[0036] Figure 8B yes Figure 8A A schematic side view of a leaf spring in its installed state;

[0037] Figure 9A yes Figure 7 A schematic perspective view of a leaf spring in its installed state;

[0038] Figure 9B yes Figure 9A A schematic side view of a leaf spring.

[0039] In the figures, embodiments of the present invention are shown in a simplified manner for clarity. Similar reference numerals in the figures refer to similar parts.

[0040] List of reference numerals

[0041] 1 Vehicle motor assembly

[0042] 10 motor covers

[0043] 20 Gearbox Assembly

[0044] 21 threaded hole

[0045] 30 circuit boards

[0046] 31 through hole

[0047] 40 Circuit Board Cover

[0048] 50 Hall effect sensor

[0049] 60 capacitor

[0050] 70 brush plate system

[0051] 71 brush board

[0052] 72 Brush tube

[0053] 73 Brush

[0054] 74 Inductor element

[0055] 75 Socket

[0056] 76 Torsion spring

[0057] 80 Motor shaft

[0058] 100 Vehicle motor assembly

[0059] 110 Motor housing

[0060] 120 Gearbox assembly

[0061] 150 Hall sensor

[0062] 160 Capacitor

[0063] 170 Brush plate system

[0064] 171 Brush plate

[0065] 171a Upper side of brush plate

[0066] 171b Lower side of brush plate

[0067] 171c Positioning pin

[0068] 171d Positioning groove

[0069] 173 Brush

[0070] 174 Inductor element

[0071] 175 Socket

[0072] 176 Leaf spring

[0073] 176a First segment

[0074] 176a-1 First part

[0075] 176a-2 Second part

[0076] 176b Second segment

[0077] 176c Third segment

[0078] 176d Square-shaped frame part

[0079] 176e Protruding tab

[0080] 177 Damping member

[0081] 178 Retaining plate

[0082] 178a bump

[0083] 179 Fixed Support Section

[0084] 179a slot

[0085] 180 motor shaft Detailed Implementation

[0086] For ease of description, directional terms are used below, referring to the orientation shown in the attached diagram. It is understood that the actual orientation used may differ.

[0087] The following reference Figures 4-9B Embodiments of this utility model are described below. Figure 4 A schematic exploded view of the motor assembly 100 is shown. As shown, the motor assembly 100 includes a motor housing 110, a gearbox assembly 120, a motor (not shown), and a brush plate system 170. Motor components (such as the armature, commutator, and motor shaft 180) are assembled in the motor housing 110, wherein one end of the motor shaft 180 is supported within the motor housing 110, and the other end extends into the gearbox assembly 120 to transmit the rotational motion of the armature (not shown) to a transmission mechanism (also not shown) within the gearbox assembly 120.

[0088] Figures 5-5B The brush plate system 170 shown includes a brush plate 171 having an upper side 171a and a lower side 171b; a brush 173; an inductor 174; and a socket 175. (See reference...) Figure 4 The upper side 171a is the side of the brush plate system 170 facing the gearbox assembly 120, and the lower side 171b is the side facing the motor cover 110.

[0089] Figure 5 This is a schematic perspective view taken from the upper side 171a of the brush plate 171. As shown, the brush plate system 170 also integrates a single Hall sensor 150 and a corresponding single capacitor 160, which are soldered to the upper side 171a of the brush plate 171. The Hall sensor 150 has two output pins. For this purpose, a positioning pin 171c for connecting the four pins of the Hall sensor 150 is provided on the upper side 171a of the brush plate 171. The positioning pin 171c has positioning grooves 171d for placing the pins. The two pins of the capacitor 160 are also connected to the positive and negative power supply pins of the Hall sensor, respectively.

[0090] In this example, the Hall sensor 150 and the capacitor 160 are separate components, as shown below: Figure 5A and Figure 5B As shown, they can also be integrated into a single component.

[0091] Figure 6This is a schematic perspective view taken from the lower side 171b of the brush plate 171. As shown, the brush plate system 170 includes a brush arm configured as a leaf spring 176. The leaf spring 176 extends in a direction transverse to the longitudinal axis of the brush 172, with one end fixed to the brush plate 171 and the other end snapped into the rectangular end of the brush 172 away from the center of the brush plate. Both the brush 172 and the leaf spring 176 are positioned on the lower side 171b of the brush plate 171.

[0092] Figure 6 Also shown are a retaining plate 178 and a fixing support 179, which are arranged on the brush plate 171 at 90-degree intervals from the associated brush 172 in the circumferential direction of the brush plate 172. A leaf spring 176 is riveted to the retaining plate 178. The fixing support 179 defines a slot 179a (see...). Figure 8B The retaining plate 178 is inserted into the slot 179a. The fixing support 179 can be integrally formed with the brush plate 171 during injection molding of the brush plate.

[0093] The leaf spring 176 has a three-section structure. The first section 176a extends perpendicular to the longitudinal axis of the brush 172, and its plane is also perpendicular to the longitudinal axis of the brush 172. The second section 176b is fixed to the retaining plate. The third section 176c is a curved transition section located between the first and second sections, with a thickness less than the first section, allowing the first section to rotate relative to the second section, thus forming the leaf spring. As shown in the figure, the first section 176a includes a first part 176a-1 with a generally parallelogram cross-section, fixed to the brush 172, and a second part 176a-2 with a generally trapezoidal cross-section, forming an obtuse angle with the first part 176a-1. Furthermore, in Figure 5 Installation status (see also) Figures 9A-9B Under these conditions, the leaf spring 176 applies a biasing force to the brush 172, wherein the first part 176a-1 is perpendicular to the second part 176b, and the second part 176a-2 forms an obtuse angle of 111 degrees with the second part 176b. This obtuse angle can also be 104 degrees, 105 degrees, 106 degrees, or 107 degrees. During assembly, the second part can initially form a 120-degree angle with the second part.

[0094] Figure 6 A damping member 177 is also shown, which has a roughly trapezoidal cross-section, consistent with the second part 176a-2 of the first segment 176a of the leaf spring 176. The damping member 177 is mounted on the brush plate 171 and abuts against the second part 176b of the leaf spring 176 from the outside.

[0095] Figure 7 The leaf spring 176 is shown in the installed state, in which the second part 176a-2 and the second segment 176b form an obtuse angle of 111 degrees, and the second segment 176b is riveted to the retaining plate 178. Figure 7The snap-fit ​​end of the leaf spring 176 is also shown to be a U-shaped section 176d, with protrusions 176e on all four sides, which are slightly inclined toward the center. In addition, two reinforcing ribs are provided on the third section 176c.

[0096] Figures 8A-8B The figures show a perspective view and a side view of the assembly of the leaf spring 176, the fixing plate 178, and the fixing support 179 in the installed state. In the installed state, the second part 176a-2 and the second segment 176b form an obtuse angle of 111 degrees, while in the uninstalled state, the second part 176a-2 and the second segment 176b form an acute angle of 80 degrees. As shown, the upper side of the retaining plate 178 is provided with several protrusions 178a to facilitate insertion into and positioning of the fixing support 179 in the slot 179a.

[0097] The inventors tested the performance of the leaf spring 176 constructed according to this utility model. The leaf spring is made of copper-beryllium alloy, the retaining plate is made of brass, and the fixing support is made of PA6+GF30. During testing, a force was applied to the leaf spring, pushing the first segment relative to the second segment from 80 degrees to 120 degrees (equivalent to the angle during assembly), then from 80 degrees to 111 degrees (equivalent to the angle in the installed state, i.e., the working angle). The leaf spring was then held at this angle, and vibration was applied to it. Each vibration cycle included rotating the first segment of the leaf spring 0.003 degrees to the left and then 0.003 degrees to the right relative to the second segment. Similarly, tests were conducted at working angles of 107 degrees, 106 degrees, 105 degrees, and 104 degrees. Figures 9A-9B As shown. The test results show that the alternating stress caused by the vibration cycle in the leaf spring (especially the third section) constructed in this utility model is much less than the bearing limit of the leaf spring material. After experiencing the required vibration cycle, the fatigue damage value of the leaf spring at each working angle is much less than 1, and the accumulated fatigue damage value is also less than 1, indicating that the leaf spring can still work normally after the required service life.

[0098] In some cases, the features disclosed in this invention may be used independently of other features. On the other hand, when necessary, the features disclosed in this invention may be combined to provide various combinations.

[0099] The wording and expressions used in this invention are illustrative and not restrictive, and therefore are not intended to exclude any equivalent examples of the illustrated and described features from the scope of this invention. Various modifications, variations, and substitutions may exist within the scope of the claims. The claims are intended to cover all such equivalent examples.

Claims

1. A brush plate system, comprising a brush plate and brushes, characterized in that, The brush plate system also includes a brush arm extending in a direction transverse to the longitudinal axis of the brush, one end of which is fixed to the brush plate and the other end of which is fixed to the end of the brush away from the center of the brush plate; and a damping member mounted on the brush plate and abutting against the brush arm from the outside.

2. The brush plate system according to claim 1, characterized in that, The brush arm is constructed of leaf springs, with the plate plane transverse to the longitudinal axis of the brush.

3. The brush plate system according to claim 2, characterized in that, The brush plate system also includes a retaining plate and a fixed support, which are arranged at 90-degree intervals from the brushes along the circumferential direction of the brush plate. The leaf spring is fixed to the fixed plate, and the fixed support is provided with a slot for the retaining plate to be inserted.

4. The brush plate system according to claim 2 or 3, characterized in that, The leaf spring consists of three sections. The first section extends along the longitudinal axis of the brush, and the plate plane is also perpendicular to the longitudinal axis of the brush. The second section is fixed to the retaining plate. The third section is a bending transition section located between the first and second sections.

5. The brush plate system according to claim 4, characterized in that, The first section includes a first part fixed to the brush and a second part forming an obtuse angle with the first part. The damping member abuts against the second part. In the uninstalled state, the second part forms an acute angle with the second section. In the installed state, the leaf spring applies a biasing force to the brush. The first part is perpendicular to the second section, and the second part forms an obtuse angle with the second section. The third section is provided with reinforcing ribs.

6. The brush plate system according to claim 2 or 3, characterized in that, The leaf spring and the brush are fixed to each other by a snap-fit ​​mechanism. The snap-fit ​​end of the leaf spring is U-shaped with protrusions on all four sides. The corresponding snap-fit ​​end of the brush is square-shaped with the protrusions tilted towards the center to hold the brush in place.

7. The brush plate system according to any one of claims 1-3, characterized in that, The brush plate has an upper side and a lower side. The brush plate system also integrates a Hall sensor and a capacitor, which are located on the upper side of the brush plate, while the brush and brush arm are located on the lower side of the brush plate.

8. The brush plate system according to claim 7, characterized in that, Hall sensors and capacitors can be separate components or integrated into a single component.

9. The brush plate system according to claim 7, characterized in that, Both the Hall sensor and the capacitor are soldered to the corresponding connection terminals on the upper side of the brush plate.

10. The brush plate system according to claim 7, characterized in that, The upper side of the brush plate is provided with a positioning pin for connecting the pins of the Hall sensor. The positioning pin has a positioning groove to place the pins. The two pins of the capacitor are respectively connected to the corresponding pins of the Hall sensor.

11. A vehicle motor assembly, comprising a motor housing, a motor mounted in the motor housing, and a gearbox assembly, characterized in that... It also includes a brush plate system according to any one of claims 1-10, the brush plate system being assembled between the gearbox assembly and the motor housing, with one end of the motor shaft supported inside the motor housing and the other end extending through the brush plate system into the gearbox assembly.

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