Brush Holder Assembly

Abstract

A brush assembly for use in a brush holder assembly of an electrical device is disclosed. The brush assembly includes a carbon brush, a conductive terminal, and a conductive lead assembly attached to both the carbon brush and the conductive terminal. In some examples, the conductive lead assembly includes a splice joint located between the conductive terminal and the carbon brush and spaced apart from both the conductive terminal and the carbon brush. In some examples, the conductive terminal includes an inner core layer located between a first conductive metal layer and a second conductive metal layer.

Description

[Technical field]

[0001] The present disclosure relates generally to brush and brush holder assemblies that may be used in electrical equipment and / or slip ring assemblies. More particularly, the present disclosure relates to a brush holder assembly configured to hold a brush in contact with a conductive moving surface. [Background technology]

[0002] The purpose of brushes in electrical equipment is to pass electrical current from a fixed contact to a moving contact surface or vice versa. Brushes and brush holders are used in electrical equipment such as generators, electric motors and / or slip ring assemblies, and sliding connection applications such as slip ring assemblies on rotating equipment such as rotating cranes and linear sliding connections on monorails. Brushes in many electrical equipment are blocks or other structures of conductive material such as graphite, carbon graphite, electrographite, metallic graphite, etc., that are configured to contact a conductive surface or a surface that will carry electrical current. Conductive lead wires or shunts extend from the brush to provide an electrical path to and / or from the brush on another conductive member.

[0003] In some designs, a brush-house type brush holder or other type of brush holder is used to support the brushes that contact the moving contact surfaces of the electrical equipment during operation. The brushes and brush housings are designed to allow the brushes to slide within the brush housing to maintain contact between the brushes and the moving contact surfaces they contact. Described herein are brushes, brush holders, related components, and methods of making the brushes, brush holders, and related components. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE PRESENT EMBODIMENT An object of the present invention is to provide a brush holder assembly. [Means for solving the problem]

[0005] A first example includes a carbon brush, a conductive terminal, and a conductive lead assembly attached to both the carbon brush and the conductive terminal, the conductive lead assembly being located between the conductive terminal and the carbon brush and having a splice joint spaced apart from both the conductive terminal and the carbon brush.

[0006] Additionally or alternatively, the conductive lead assembly includes a first lead wire coupled to a second lead wire at a splice joint. Additionally or alternatively, a first lead wire is secured to the conductive terminal and extends from the conductive terminal to the splice joint, and a second lead wire is secured to the carbon brush and extends from the carbon brush to the splice joint.

[0007] Additionally or alternatively, the splice joint is formed by welding a first end region of the first lead wire to a first end region of the second lead wire. Additionally or alternatively, the first lead wire has a second end region secured to the carbon brush and the second lead wire has a second end region secured to the carbon brush.

[0008] Additionally or alternatively, the splice joint is formed by welding a first end region of the first lead wire to a first end region of the second lead wire. Additionally or alternatively, the first lead wire has an intermediate region located between the first end region of the first lead wire and the second end region of the first lead wire.

[0009] Additionally or alternatively, the conductive terminal is secured to an intermediate region of the first lead wire. Additionally or alternatively, a second end region of the first lead wire is embedded in the top surface of the carbon brush at a first location and a second end region of the second lead wire is embedded in the top surface of the carbon brush at a second location, the first location being spaced apart from the second location.

[0010] Additionally or alternatively, a portion of the intermediate region of the first lead wire is welded to at least one of the first end region of the first lead wire and the first end region of the second lead wire at the splice joint.

[0011] Additionally or alternatively, the splice joint has wear marks which are used as reference points to determine wear loss of the carbon brush. Additionally or alternatively, the splice joint is formed by welding the first and second end regions of the first lead wire to the first end region of the second lead wire.

[0012] Additionally or alternatively, the first lead wire has an intermediate region located between a first end region of the first lead wire and a second end region of the first lead wire, the intermediate region of the first lead wire being secured to the conductive terminal.

[0013] Additionally or alternatively, an intermediate region of the first lead wire is ultrasonically welded to the conductive terminal. Additionally or alternatively, the conductive lead assembly includes a third lead wire coupled to the first and second lead wires at a splice joint.

[0014] Additionally or alternatively, the splice joint is formed by welding the first end region and the second end region of the first lead wire to the first end region of the second lead wire and the first end region of the third lead wire.

[0015] Additionally or alternatively, a second end region of the second lead wire is embedded in the upper surface of the brush at a first location and a second end region of the third lead wire is embedded in the upper surface of the brush at a second location, the first location being spaced apart from the second location.

[0016] Additionally or alternatively, the conductive terminal includes an inner core layer located between the first conductive metal layer and the second conductive metal layer. Additionally or alternatively, the inner core layer includes steel.

[0017] Additionally or alternatively, the first conductive metal layer, the second conductive metal layer, or both the first and second conductive metal layers comprise copper. Another example is a method of manufacturing a brush assembly. The method includes welding a first end region of a first lead wire to a first end region of a second lead wire. Prior to the welding step, the first lead wire is pre-secured to the conductive terminal and the second lead wire is pre-secured to the carbon brush. The welding forms a splice joint between the first lead wire and the second lead wire. The splice joint is between the carbon brush and the conductive terminal and spaced apart from the carbon brush and the conductive terminal.

[0018] Additionally or alternatively, before the first lead wire is secured to the conductive terminal, the second end region of the second lead wire is embedded in a first position on the top surface of the brush and the second end region of the second lead wire is embedded in a second position on the top surface of the brush.

[0019] Additionally or alternatively, the first lead wire has an intermediate region located between the first end region of the first lead wire and the second end region of the first lead wire, and a conductive terminal is secured along the intermediate region of the first lead wire.

[0020] Additionally or alternatively, the first lead wire is longer than the second lead wire, and the conductive terminal is secured along an intermediate region of the first lead wire at a position closer to the first end region of the first lead wire than to the second end region of the first lead wire.

[0021] Additionally or alternatively, the welding step includes welding a portion of the intermediate region of the first lead wire to at least one of the first end region of the first lead wire and the first end region of the second lead wire at the splice joint.

[0022] Additionally or alternatively, prior to the welding step, the first end region of the first lead wire, the first end region of the second lead wire and the intermediate region of the first lead wire are positioned in a welding fixture such that the first end region of the first lead wire overlaps the first end region of the second lead wire.

[0023] Additionally or alternatively, the method includes forming wear marks on a surface of the splice joint. Additionally or alternatively, the welding step further includes welding the second end region of the first lead wire to the first end region of the third lead wire at a splice joint.

[0024] Additionally or alternatively, the method includes, prior to the welding step, positioning the first and second end regions of the first lead wire in a welding fixture, positioning the first end region of the second lead wire in the welding fixture, and positioning the first end region of the third lead wire in the welding fixture, such that the first end region of the first lead wire overlaps the first end region of the second lead wire and the second end region of the first lead wire overlaps the first end region of the third lead wire.

[0025] Additionally or alternatively, the method includes welding a first end region of a third lead wire to the first end region of the first lead wire and to the first end region of the second lead wire at a splice joint, the third lead wire being pre-secured to the carbon brush prior to the welding step.

[0026] Another example is a brush holder assembly for placing a conductive carbon brush in contact with a conductive surface of an electrical device. The assembly includes a brush holder having a brush housing and a beam secured to the brush housing, a carbon brush slidably disposed within the brush housing, and a conductive terminal removably attached to the beam of the brush holder. The assembly further includes a first lead wire secured to the conductive terminal and a second lead wire secured to the carbon brush and extending therefrom. A first end region of the first lead wire is secured to a first end region of the second lead wire at a splice joint. The splice joint is located between the carbon brush and the conductive terminal and spaced from the carbon brush and the conductive terminal.

[0027] Additionally or alternatively, the first end region of the first lead wire is ultrasonically welded to the first end region of the second lead wire at a splice joint. Additionally or alternatively, the first lead wire has an intermediate region located between the first end region of the first lead wire and the second end region of the first lead wire, and a conductive terminal is secured along the intermediate region of the first lead wire.

[0028] Additionally or alternatively, the first lead wire is longer than the second lead wire, and the conductive terminal is secured along an intermediate region of the first lead wire at a position closer to the first end region of the first lead wire than to the second end region of the first lead wire.

[0029] Additionally or alternatively, a second end region of the first lead wire is embedded in the top surface of the brush at a first location and a second end region of the second lead wire is embedded in the top surface of the brush at a second location, the first location being spaced apart from the second location.

[0030] Additionally or alternatively, the splice joint is formed by welding together a first end region of the first lead wire, a second end region of the first lead wire and a portion of a middle region of the first lead wire.

[0031] Additionally or alternatively, the splice joint is formed by welding the first and second end regions of the first lead wire to the first end region of the second lead wire.

[0032] Additionally or alternatively, the conductive terminal includes an inner core layer located between the first conductive metal layer and the second conductive metal layer. Additionally or alternatively, the splice joint has wear marks which are used as reference points to determine wear loss of the carbon brush.

[0033] Another example brush assembly includes a carbon brush having an upper surface and a lower surface, a conductive terminal, and a conductive lead assembly attached to both the carbon brush and the conductive terminal. The conductive terminal has an inner core layer located between a first conductive metal layer and a second conductive metal layer.

[0034] Additionally or alternatively, the conductive lead assembly is welded directly to the first conductive metal layer of the conductive terminal. Additionally or alternatively, the inner core layer includes steel.

[0035] Additionally or alternatively, the first conductive metal layer, the second conductive metal layer, or both the first and second conductive metal layers comprise copper. Additionally or alternatively, the conductive lead assembly has a splice joint located between the conductive terminal and the carbon brush and spaced apart from both the conductive terminal and the carbon brush.

[0036] Additionally or alternatively, the conductive lead assembly includes a first lead wire coupled to a second lead wire at a splice joint. Additionally or alternatively, a first lead wire is secured to the conductive terminal and extends from the conductive terminal to the splice joint, and a second lead wire is secured to the carbon brush and extends from the carbon brush to the splice joint.

[0037] Additionally or alternatively, the splice joint is formed by welding a first end region of the first lead wire to a first end region of the second lead wire. Additionally or alternatively, the first lead wire has an intermediate region located between a first end region of the first lead wire and a second end region of the first lead wire, the second end region of the first lead wire being fixed to the carbon brush and the intermediate region of the first lead wire being fixed to the conductive terminal.

[0038] Additionally or alternatively, a portion of the intermediate region of the first lead wire is welded to at least one of the first end region of the first lead wire and the first end region of the second lead wire at the splice joint.

[0039] Additionally or alternatively, the splice joint is formed by welding the first and second end regions of the first lead wire to the first end region of the second lead wire.

[0040] The above summary of some embodiments, aspects and / or examples is not intended to describe each embodiment or every implementation of the present disclosure, which are more particularly illustrated in the figures and detailed description that follow.

[0041] Aspects of the present disclosure will become more fully understood from consideration of the following detailed description of various embodiments in conjunction with the accompanying drawings. [Brief description of the drawings]

[0042] [Figure 1] 1 is an illustration of an exemplary brush holder assembly positioned adjacent a rotating component of an electrical device. [Diagram 2] 2 is an exploded view of the components of the example brush holder assembly of FIG. 1; [Diagram 3] 2 illustrates a brush assembly of the example brush holder assembly of FIG. 1; [Figure 4] 4 is an exploded view of the brush assembly shown in FIG. 3 of an exemplary brush holder assembly. [Diagram 5] FIG. 2 illustrates lead wires for the example brush holder assembly of FIG. 1. [Figure 6] 6 shows the lead wire of FIG. 5 shaped for use in a brush holder assembly; [Figure 7] 2 illustrates a terminal of the example brush holder assembly of FIG. 1; [Figure 8] 8 illustrates the coupling of the terminal of FIG. 7 to the lead wire of FIG. 5 or 6 prior to being secured to the lead segment during manufacturing. [Figure 9] 9 is a diagram showing a state after the terminal and the lead wire shown in FIG. 8 are fixed to each other. [Figure 10] 2 illustrates an additional lead wire of the example brush holder assembly of FIG. 1. [Figure 11] FIG. 11 shows the part of FIG. 10 molded for use in a brush holder assembly. [Figure 12] 11 illustrates the lead wire of FIG. 10 after being attached to a brush of the example brush holder assembly of FIG. 1 . [Figure 13] 2A-2C illustrate example fasteners for fastening together ends of the lead wires of the example brush holder assembly of FIG. 1. [Figure 14]14 illustrates the lead wires of the exemplary brush holder assembly positioned along the exemplary fixture shown in FIG. 13 before being secured together. [Figure 15] 15 shows the lead wires of the brush holder assembly shown in FIG. 14 after they have been secured together. [Figure 16A] FIG. 16 is a front view of a brush assembly of the exemplary brush holder shown in FIG. 15 . [Figure 16B] FIG. 16 is a side view of a brush assembly of the exemplary brush holder shown in FIG. 15 . [Figure 17] 1 is an illustration of an exemplary brush holder assembly positioned adjacent a rotating component of an electrical device. [Figure 18] FIG. 13 illustrates terminals attached to lead wires of another example brush holder assembly. [Figure 19] 19 illustrates the lead wires of the example brush holder assembly shown in FIG. 18 before they are secured together. [Figure 20] 20 illustrates the lead wires of the example brush holder assembly shown in FIG. 19 positioned along an example fixture before being secured together. [Figure 21] 21 shows the lead wires of the brush holder assembly shown in FIG. 20 after they have been secured together. [Figure 22] 22 is an illustration of the exemplary brush holder assembly shown in FIG. 21 positioned adjacent to a rotating component of an electrical device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] While aspects of the present disclosure are susceptible to various modifications and alternative forms, certain of which are shown by way of example in the drawings and will be described in detail. However, aspects of the present disclosure are not limited to the specific embodiments described. The present invention encompasses all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.

[0044] For the following defined terms, the following definitions shall apply, unless a different definition is set forth in the claims or this specification. In this specification, all numerical values, whether explicitly stated or not, are deemed to be modified by the word "about". The word "about" generally refers to a range of numerical values ​​that one of ordinary skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many cases, the word "about" includes a number that is rounded to the nearest significant figure.

[0045] The recitation of numerical ranges by endpoints includes all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5). Although some optimal dimensions, ranges and / or values ​​for various components, features and / or specifications are disclosed, a person skilled in the art can understand from the disclosure herein that the preferred dimensions, ranges and / or values ​​may differ from those expressly set forth herein.

[0046] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless expressly stated otherwise. As used in this specification and the appended claims, the term "or" is intended to include the meaning "and / or" unless expressly stated otherwise.

[0047] In the following description, reference is made to the figures, in which similar parts in different figures are given the same reference numerals. The detailed description and drawings disclosed herein depict exemplary embodiments and are not intended to limit the scope of the invention. Additionally, the drawings are not necessarily to scale. The exemplary embodiments are intended to be illustrative of the invention only. Unless otherwise specified, certain features of the exemplary embodiments may be incorporated into other embodiments.

[0048] 1 illustrates an exemplary system 10 that includes a brush-holder assembly 12. In some respects, the brush-holder assembly 12 has similarities to the brush-holder assembly described in U.S. Patent No. 7,034,430, entitled "BRUSH HOLDER APPARATUS, BRUSH ASSEMBLY AND METHOD," which is incorporated by reference herein in its entirety. However, the exemplary system 10 includes features as described herein.

[0049] As shown in FIG. 1, the brush holder assembly 12 includes a brush holder 16 within which the carbon brush 14 is disposed. FIG. 1 shows that in some examples, the brush holder 16 includes multiple guide surfaces (e.g., brush housing) that surround one or more sides of the brush 14 to guide the linear or longitudinal movement of the brush 14 toward the conductive surface 18 of the rotating component 20. That is, as the brush 14 wears, it moves linearly within an opening defined by the multiple guide surfaces of the brush holder 16. In some embodiments, the brush holder 16 is not box-shaped, but includes one or more guide surfaces, such as grooves, posts, struts, etc., that abut and / or surround one or more sides of the brush 14 and / or extend or penetrate the brush 14 or a portion thereof to guide the linear or longitudinal movement of the brush 14.

[0050] As further shown in FIG. 1, in some embodiments, a handle 22 is coupled to or otherwise provided on the holder assembly 12 (including the brush holder 16) to facilitate engagement and disengagement of the brush 14 from the conductive surface 18.

[0051] 1 also shows that the brush 14 has a first or upper end face 24, a second or lower end face 26, and a length extending therebetween. The second end face 26 is in electrical contact with a conductive surface 18 of a moving (rotating, sliding, etc.) part 20 of an electrical device (e.g., a collector ring, slip ring, or commutator) to conduct electrical current from the conductive surface 18. The brush holder assembly 12 is configured to place the brush 14 in contact with a conductive surface 18, such as a surface of a rotating part 20 of an electrical device. The brush 14 extends from a lower edge of the brush holder 16 such that the second end face 26 of the brush 14 engages the conductive surface 18.

[0052] 1, the brush assembly 12 includes an upper beam 30 and a lower beam 32 that are hingedly or pivotally coupled to one another. When the upper beam 30 and the lower beam 32 are aligned with one another (e.g., when the longitudinal axis of the upper beam 30 is parallel to the longitudinal axis of the lower beam 32), the brush holder 16 can be considered to be in an engaged or locked position such that the brushes 14 are adjacent to or in direct electrical contact with the conductive surface 18.

[0053] As further shown in FIG. 1, the brush holder assembly 12 includes a wear condition monitor 38 and a spacer 40. Additional aspects of the wear condition monitor 38 and associated structure and function are described in U.S. Patent Application Publication Nos. 2020 / 0112133 and 2020 / 0112223, the disclosures of which are incorporated herein by reference. The spacer 40 is attached to the first end surface 24 of the brush 14. As further shown in FIG. 1, the wear condition monitor 38 is coupled to a spring 41. In some examples, a portion of the spring 41 is coiled around a portion of the wear condition monitor 38, and a long portion of the spring 41 extends from the coiled portion. Thus, the wear condition monitor 38 is disposed within the coiled portion of the spring 41.

[0054] Thus, in some examples, the wear condition monitor 38 may be mounted adjacent to a surface of the spring 41 or may be mounted inside the spring 41, such as within a coiled portion of the spring 41. The spring 41 may be a constant force spring that provides tension to the brush 14, the wear condition monitor 38, or both the brush 14 and the wear condition monitor 38, urging the brush 14 toward and into contact with the conductive surface 18 of the rotating component 20. That is, the spring 41 has a coiled portion designed to provide a force that urges the brush 14 into engagement with the rotating component 20 of an electrical device, such as a slip ring or commutator.

[0055] 1, the brush holder assembly 12 includes a conductive wire assembly 36 that extends from the first end surface 24 of the brush 14 to one or more different components of the brush holder assembly 12 for conducting electricity from the brush 14 to a terminal 42. For example, the conductive wire assembly 36 extends from the first end surface 24 of the brush 14 and is attached to a terminal 42, which is attached to a mounting block (not shown), a portion of the lower beam 32, a portion of the upper beam 30, or a portion of both the lower beam 32 and the upper beam 30. While not shown for simplicity, in some examples, the lower beam 32 is removably engaged to another structure, such as a mounting block (not shown).

[0056] As previously mentioned, the brush holder assembly 12 is configured to maintain the conductive surface 26 of the brush 14 in contact with the conductive surface 18 of the rotating part 20. When an electrical current is generated by an electrical device (e.g., a collector ring, slip ring, or commutator), the current flows through the moving (rotating, sliding, etc.) part 20 to the brush 14. This causes the current to travel through the conductive lead assembly 36 to the terminal 42. In turn, the terminal 42 is engaged with a mounting block (not shown) to allow current to flow to and from the mounting block.

[0057] Figure 2 is an exploded view of the various components of the brush holder assembly 12 shown in Figure 1. Specifically, Figure 2 shows the conductive lead assembly 36, the terminals 42 and the brushes 14, all of which are positioned apart (for ease of viewing) from the remainder of the brush holder assembly 12. The dashed lines in Figure 2 indicate the alignment of each component (e.g., the terminals 42, the conductive lead assembly 36 and the brushes 14) with the lower beam 32 of the brush holder assembly 12. Note that for simplicity, the wear condition monitor 38, the spacer 40 and the spring 41 have been omitted from Figure 2.

[0058] As shown in FIG. 2, the conductive electrical lead assembly 36 includes a first electrical lead wire 46. As will be described in more detail below, the first electrical lead wire 46 is spliced ​​with a second electrical lead wire 44a and / or a third electrical lead wire 44b to form a splice joint (e.g., splice joint, weld joint) along the conductive lead assembly 36. Referring back to FIG. 1, in a fully assembled condition, the second electrical lead wire 44a and the third electrical lead wire 44b form a portion of the conductive electrical assembly 36 that is attached to the brush 14 (as will be described in more detail below, with portions of the second electrical lead wire 44a and the third electrical lead wire 44b embedded within the brush 14). Additionally, as shown in FIG. 1, in a fully assembled condition, the first electrical lead wire 46 is attached (e.g., welded) to a terminal 42, which is removably attached to the lower beam 32 (as will be described in more detail below).

[0059] 3 illustrates a brush assembly 45 of the brush holder assembly 12 (shown in FIG. 2) having a conductive electrical lead assembly 36 attached to both the terminal 42 and the brush 14. The conductive electrical lead assembly 36 extends between the terminal 42 and the brush 14. As described below, it may be preferable to attach a first electrical lead wire 46 of the conductive electrical lead assembly 36 to the terminal 42 in a separate manufacturing step and attach a second electrical lead wire 44a and / or a third electrical lead wire 44b to the brush 14 in another separate manufacturing step before splicing (e.g., bonding, attaching, connecting, etc.) the second electrical lead wire 44a and / or the third electrical lead wire 44b to the first electrical lead wire 46 to construct the overall brush assembly 45 shown in FIG. 3. The combined structure of the terminal 42, conductive electrical lead assembly 36 and brush 14 shown in FIG. 3 is then coupled to the remaining components of the brush holder assembly 12 to form the system 10 shown in FIG. 1. When the brushes 14 become worn during use, the worn brush assembly 45 (including the terminals 42, conductive electrical lead assembly 36 and worn brushes 14) can be removed from the brush holder of the brush holder assembly 12 and replaced with another new brush assembly 45 with a new, unused brush 14 and associated terminals 42 and conductive electrical lead assembly 36.

[0060] FIG. 4 is an exploded view of some of the components of the brush assembly 45 shown in FIG. 3. For ease of illustration, the brushes 14 have been omitted from FIG. 4. In FIG. 4, the terminals 42 are shown spaced apart from the conductive electrical lead assembly 36. Additionally, as shown in FIG. 4, the conductive electrical lead assembly 36 also includes a band 48 (shown spaced apart from the conductive electrical lead assembly 36). Although the band 48 is shown attached to the first electrical lead wire 46 above the splice 50, the band 48 may be attached to the second electrical lead wire 44a and / or the third electrical lead wire 44b below the splice 50 without changing the performance or functionality of the system 10 or its individual components. In some examples, the band 48 is a clip, strap, or other structure configured to surround an end region of the first electrical lead wire 46 near the splice 50 (or in other embodiments, to surround the second electrical lead wire 44a and / or the third electrical lead wire 44b).

[0061] As can be seen in Figure 4, the terminal 42 includes one or more features designed to engage with the lower beam 32 and / or mounting block (not shown) of the brush holder assembly 12. For example, as shown in Figure 4, the terminal 42 has a first side wall 55a and a second side wall 55b (not shown in Figure 4, but shown in Figure 7). The first side wall 55a and the second side wall 55b are each designed to removably couple, such as by engaging, mating, with a portion of the lower beam 32 and / or mounting block, thereby securing the terminal 42 to the lower beam 32 and / or mounting block and allowing electrical current to flow therebetween.

[0062] As further shown in FIG. 4, the terminal 42 has a first engagement arm 56a and a second engagement arm 56b. Together with the first side wall 55a and the second side wall 55b, the first engagement arm 56a and the second engagement arm 56b are designed to slidably engage a portion of the lower beam 32. For example, the first engagement arm 56a and the second engagement arm 56b have tip regions 58a / 58b, respectively, that are designed to engage a portion of the lower beam 32. For example, the first engagement arm 56a and the second engagement arm 56b are designed to slide (e.g., hook, clip, etc.) over a portion of the lower beam 32 with the first and second engagement arms 56a / 56b disposed on a first side of the rear wall and the first and second side walls 55a / 55b of the lower beam 32 and the lower surface 59 disposed on a second side opposite the rear wall of the lower beam 32. 4, the terminal 42 defines a gap between the lower surface 59 and the tip regions 58a / 58b of the first and second engagement arms 56a, 56b, and a portion of the lower beam 32 can slide within the gap. That is, coupling the terminal 42 to the lower beam 32 includes sliding a portion of the rear wall of the lower beam 32 between the lower surface 59 and both of the tip regions 58a / 58b of the first and second engagement arms 56a, 56b, respectively.

[0063] As further shown in FIG. 4, the lower surface 59 has a tab 60 (e.g., a protrusion, projection, bump, etc.) extending or projecting away from the surface of the lower surface 59. The tab 60 engages a mating opening (not shown in FIG. 4) located in a portion of the lower beam 32. The tab 60 is used to hold the terminal in proper alignment with the lower beam 32 and / or a mounting block (not shown) when engaging and disengaging the brush holder assembly 12 from an electrical device. Furthermore, the engagement of the tab 60 with the opening located in the lower beam 32 forms a mating connection between the terminal 42 and the lower beam 42 that can removably couple the terminal 42 to the lower beam 32. The engagement of the terminal 42 with the lower beam 32 by the mating engagement of the tab 60 with the opening in the lower beam 32 can increase the threshold force required to remove the terminal 42 from the lower beam 32. As a result, the terminal 42 is prevented from being unintentionally removed from the lower beam 32 when the system 10 is attached to an electrical device.

[0064] 4, terminal 42 has a mounting surface 54. Mounting surface 54 is coplanar with lower surface 59 (e.g., mounting surface 54 and lower surface 59 are a continuous flat sheet of material). Mounting surface 54 of terminal 42 can be defined as the portion of terminal 42 that is secured, such as by welding, to a portion of first electrical lead wire 46.

[0065] As further shown in FIG. 4, a portion of the first electrical wire lead 46 includes an attachment region 52 that is designed to be secured, such as by welding, to an attachment surface 54 of the terminal 42 (FIG. 3 illustrates the attachment region 52 of the first electrical wire lead 46 welded to the attachment surface 54 of the terminal 42 shown in FIG. 4). Note that in FIG. 4, the attachment region 52 along a portion of the first electrical wire lead 46 is illustrated as a substantially flat surface. However, as will be described in more detail below, the shape of the attachment region 52 of the first electrical wire lead 46 may be a shape that results from welding the attachment region 52 to the attachment surface 54 of the terminal 42. That is, the first electrical wire lead 46 may be substantially cylindrical along the attachment region 52 prior to being welded to the attachment surface 54.

[0066] Further, as can be seen in both FIG. 3 and FIG. 4, the terminal 42 has a first opening 57a and a second opening 57b, which are located on either side of the terminal 42 adjacent the terminal 42 between the mounting surface 54 of the terminal 42 and the first and second engagement arms 56a / 56b. The openings 57a / 57b are defined by the particular geometric shape of the first engagement arm 56a and the second engagement arm 56b. For example, the first engagement arm 56a and the second engagement arm 56b have a shape (e.g., a bent shape, a curved shape) that defines (together with the mounting surface 54) the first opening 57a and the second opening 57b. Furthermore, as shown in FIG. 3 and further described below with reference to FIG. 8, the first opening 57a and the second opening 57b are designed to allow a portion of the first electrical lead wire 46 to extend therethrough.

[0067] As previously mentioned, the conductive wire assembly 36 shown in FIG. 4 includes a band 48. The band 48 is disposed on a portion of the first electrical lead wire 46. The band 48 may also be disposed on a portion of the second electrical lead wire 44a and / or the third electrical lead wire 44b. The band 48 is designed to wrap around and securely fasten the first end 47 and the second end 49 of the first electrical lead wire 46 over the splice 50 (i.e., between the splice 50 and the terminal 42). However, in some examples, the clip 48 may be removably coupled to the second electrical lead wire 44a and / or the third electrical lead wire 44b (i.e., between the splice 50 and the brush 14).

[0068] As previously mentioned (and described in more detail below with reference to FIGS. 14 and 15), constructing the conductive electrical lead assembly 36 includes splicing (e.g., ultrasonically welding) an end of the first electrical lead wire 46 to the end of the second electrical lead wire 44a and / or the third electrical lead wire 44b. Specifically, FIG. 4 illustrates a splice (e.g., weld) region 50 of the first electrical lead wire 46 to the second electrical lead wire 44a and the third electrical lead wire 44b. The splice region 50 is configured as a welded structure (e.g., weld joint, weld connection) obtained by splicing (e.g., ultrasonically welding) together the first end region 47 of the first electrical lead wire 46, the second end region 49 of the first electrical lead wire 46, the first end region 62a of the second electrical lead wire 44a, and the first end region 62b of the third electrical lead wire 44b. It should be noted that in some examples, the splice region 50 is comprised of the first end region 47 of the first electrical lead wire 46, the second end region 49 of the first electrical lead wire 46, the first end region 62a of the second electrical lead wire 44a, and the first end region 62b of the third electrical lead wire 44b. In other examples, the splice region 50 includes one or more end regions (such as only one or both end regions) of the second electrical lead wire 44a and / or the third electrical lead wire 44b spliced ​​to one or more end regions (such as only one or both end regions) of the first electrical lead wire 46. In other examples, the splice region 50 includes only one end region of the first electrical lead wire 46 joined to only one end region of the second electrical lead wire 44a or the third electrical lead wire 44b.

[0069] 5-9 and the accompanying description, exemplary manufacturing steps for attaching (eg, welding) the third electrical lead wire 46 to the terminal 42 are described. FIG. 5 illustrates the first electrical wire lead 46 in an unformed (e.g., raw material) configuration (e.g., the configuration of the first electrical wire lead 46 before being formed and welded to the terminal 42). As shown in FIG. 5, the unformed configuration of the first electrical wire lead 46 is substantially similar to a cylindrical wire having a first end region 47 (as described above with reference to FIG. 4) and a second end region 49 (as described above with reference to FIG. 4) opposite the first end region 47. In some examples, the first electrical wire lead 46 is constructed of copper. However, in other examples, the first electrical wire lead 46 may be formed of a variety of different conductive materials. For example, the first electrical wire lead 46 may be constructed of aluminum, silver, plated metal, etc.

[0070] As further shown in FIG. 5, the first electrical lead wire 46 has a multifilament structure formed from a plurality of individual wires 51 wound together along a longitudinal axis of the first electrical lead wire 46. The first electrical lead wire 46 shown in FIG. 5 includes eleven individual wires 51 wound together to form the first electrical lead wire 46. However, the first electrical lead wire 46 may have more or less than eleven individual wires 51 wound together to form the first electrical lead wire 46. For example, the first electrical lead wire 46 may be formed from 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or more individual wires 51. Additionally, although not shown, in some examples, the first electrical lead wire 46 may be formed from a single solid wire (e.g., the first electrical lead wire 46 may be formed from a single solid cylindrical wire).

[0071] Figure 6 illustrates the first electrical lead wire 46 shown in Figure 5 after it has been shaped (e.g., bent, formed, etc.) into the configuration shown in Figure 6. As previously mentioned, Figure 6 illustrates a number of individual wires 51 that are collectively wound to form the first electrical lead wire 46.

[0072] The shape of the first electrical lead wire 46 shown in Figure 6 includes a shape substantially similar to the shape of the first electrical lead wire 46 shown in Figures 1-4 and described above (e.g., the shape of the electrical lead wire 46 of the fully assembled system 10 of Figure 1). Figure 6 also shows the first electrical lead wire 46 prior to welding to the terminal 42 (the welding of the second electrical wire 46 to the terminal 42 is described below with reference to Figures 8 and 9). The terminal 42 is welded to the first electrical lead wire 46 either before or after forming the lead wire into the shape of Figure 6.

[0073] As shown in Figure 6, fabricating the pre-formed raw material first electrical lead wire 46 shown in Figure 5 into a formed configuration of first electrical lead wire 46 includes disposing a first end region 47 of wire 46 adjacent to a second end region 49 of wire 46. Additionally, as shown in Figure 6, the formed configuration of wire 46 has a curved portion 53, a portion of which includes attachment region 52 described above with reference to Figure 4.

[0074] FIG. 7 illustrates terminal 42 in a pre-formed configuration (e.g., the configuration of terminal 42 before it is formed and welded to first electrical lead wire 46). As illustrated in FIG. 7, before being formed (e.g., bent, formed, stamped, machined, etc.) into a final assembly configuration (e.g., the configuration illustrated in FIGS. 1-4), terminal 42 resembles a flat sheet. The pre-formed terminal 42 illustrated in FIG. 7 is machined (e.g., cut) from a sheet of raw material. That is, the pre-formed terminal 42 illustrated in FIGS. 1-4 is first machined (e.g., cut) from a flat sheet of material into the shape illustrated in FIG. 7. After being cut into the geometric shape illustrated in FIG. 7, it is further bent, formed, stamped, machined, etc., to form the shape of terminal 42 illustrated in FIGS. 1-4.

[0075] The pre-formed configuration of terminal 42 shown in Figure 7 has a lower surface 59, a portion of which is formed into tab 60 (described above with reference to Figure 4). The pre-formed configuration of terminal 42 also has a first sidewall 55a and a second sidewall 55b disposed adjacent lower surface 59 and extending away from lower surface 59. As shown in Figure 7, the pre-formed configuration of terminal 42 has a mounting surface 54 that defines the portion of terminal 42 that is welded to mounting region 52 (shown in Figure 4) of first electrical lead wire 46.

[0076] As shown in Figure 7, the pre-molded configuration of the terminal further includes a first engagement arm 56a and a second engagement arm 56b, both of which are disposed on opposite sides of top surface 80 and extend away from top surface 80. As shown in Figure 7, first engagement arm 56a and second engagement arm 56b each include a tip region 58a / 58b.

[0077] As previously mentioned (and described in more detail below), an exemplary manufacturing process for the system 10 includes welding (e.g., ultrasonically welding) the first electrical lead wire 46 to the terminal 42, e.g., to the mounting surface 54 of the terminal. As previously mentioned, in some examples, the first electrical lead wire 46 is formed from copper. In order to weld a copper wire to the terminal 42, at least a portion of the terminal 42 must be capable of copper welding. In other words, conventional welding techniques require that the materials being joined are materials capable of carrying out the welding process. In some examples, constructing at least a portion of the terminal 42 from copper and / or a copper alloy is advantageous when welding the first electrical lead wire 46 to the terminal 42. In some examples, the copper and copper alloys utilized herein include non-ferrous copper and non-ferrous copper alloys.

[0078] As shown in the detailed view of FIG. 7, in some examples, the terminal 42 is formed from a copper clad material. For example, the detailed view of FIG. 7 shows a cross section of a wall of the terminal 42. The cross section shown in the detailed view of FIG. 7 shows that the terminal 42 has a first copper layer 68a, a second copper layer 68b, and an inner core material 66 located between the first and second copper layers 68a / 68b. The inner core material 66 is "sandwiched" between the first copper layer 68a and the second copper layer 68b, with the first copper layer 68a extending continuously across the entire first side of the inner core material 66 and the second copper layer 68b extending continuously across the entire opposite second side of the inner core material 66. The inner core material 66 is a steel or other metallic material, such as a resilient steel. In one example, the inner core material 66 is 1065 steel having an ultimate tensile strength of about 630-690 MPa, a yield tensile strength of about 380-490 MPa, and an elastic modulus of about 190-210 GPa. In some examples, the material construction of the terminal 42 shown in the detailed view of FIG. 7 is referred to as a "copper plated" or "copper clad" material. Furthermore, when the terminal 42 is formed from a multi-layer material (e.g., plated material, clad material, copper clad steel), an exposed end of the terminal 42 is obtained in which each layer of material making up the multi-layer material is visible. In the above example, the exposed end of the copper clad steel sheet shows the first copper layer 68a, the end of the second copper layer 68b, and the inner core material 66 (e.g., steel).

[0079] Additionally, after terminal 42 is formed into its assembled configuration (as shown in FIGS. 1-4), the inner surface of terminal 42 that contacts and / or bonds to first electrical wire lead 46 is formed by second copper layer 68b. For example, second copper layer 68b is formed from a copper alloy that can be welded to copper wire 51 that forms first electrical wire lead 46.

[0080] In some examples, the entire outer surface area of ​​terminal 42 is plated with nickel after terminal 42 is formed into an assembled configuration (FIGS. 1-4). In some examples, the nickel used to plate terminal 42 is low phosphorus nickel. Low phosphorus nickel inhibits corrosion. Additionally, plating the entire outer surface of terminal 42 with a low phosphorus nickel material facilitates ultrasonic welding of first electrical lead wire 46 to terminal 42. In some examples, the thickness of the nickel plating is about 0.25-30 microns, about 0.50-15 microns, about 0.75-10 microns, about 1-5 microns, or less than 5 microns.

[0081] 7 and the above description, because the first copper layer 68a is separated from the second copper layer 68b, electrical current that reaches the second copper layer 68b through the nickel plating (such as through the conductive electrical lead assembly 36) will pass through the inner core layer 66 to reach the first copper layer 68a. Thus, electrical current can travel from the surface 18 of the rotating component 20 of the electrical device through the brush 14, the second and / or third electrical lead wires 44a and 44b, the first electrical lead wire 46, the nickel plating layer, the second copper layer 68b, the inner core layer 66, the first copper layer 68a, and then to the nickel plating layer. As a result, electrical current can reach the mounting block and pass through the mounting block.

[0082] In some examples, the inner core material 66 is formed from steel, such as 1065 steel, 1080 steel, or similar steel materials. As previously mentioned, the inner core material 66 has a first side and an opposing second side that are covered with a material different from the inner core material 66. Although the above examples describe the inner core material 66 being covered with a copper material (i.e., copper and / or copper alloys), a variety of materials (e.g., metals, metal alloys, etc.) can be used to cover each side of the inner core material 66. Examples of materials that can be used to cover each side of the inner core material 66 include silver, aluminum, cadmium alloys, or similar metals and metal alloys.

[0083] In some examples, the composition ratio of the inner core material 66, the first copper layer 68a, and the second copper layer 68b is 80 / 10 / 10. In other words, of the total thickness of the terminal 42 (not including the nickel plating layer of the material), the first copper layer 68a constitutes 10% of the total thickness, the second copper layer 68b constitutes 10% of the total thickness, and the inner core material 66 constitutes 80% of the total thickness of the terminal 42. The thickness of each layer can be adjusted as needed. For example, in some examples, the thickness of the first copper layer 68a may be about 5%, the thickness of the second copper layer 68b may be about 5%, and the thickness of the inner core material 66 may be about 90%. In other examples, the thickness of the first copper layer 68a may be about 15%, the thickness of the second copper layer 68b may be about 15%, and the thickness of the inner core material 66 may be about 70%. In another example, the thickness of the first copper layer 68a is about 5%-15%, the thickness of the second copper layer 68b is about 5%-15%, and the thickness of the inner core material 66 is about 70% to 90%.

[0084] 8 illustrates another example of a manufacturing step in the process of attaching (e.g., welding) the first electrical lead wire 46 to the terminal 42. As shown in FIG. 8, prior to welding the first electrical lead wire 46 to the terminal 42, the first electrical lead wire 46 is positioned through the openings 57a and 57b of the terminal 42 such that the attachment region 52 of the first electrical lead wire 46 is aligned (e.g., juxtaposed) with the attachment surface 54 of the terminal 42. As previously discussed, the openings 57a / 57b of the terminal 42 are defined by the first and second engagement arms 56a and 56b, respectively.

[0085] 8, prior to welding the first electrical wire lead 46 to the terminal 42, the first electrical wire lead 46 extends longitudinally along a mounting surface 54 of the terminal 42 with a first end region 47 extending from a first side of the terminal 42 and a second end region 49 extending from an opposite second side of the terminal 42. Thus, the mounting region 52 of the first electrical wire lead 46, which is a middle region of the first electrical wire lead 46, is aligned with the terminal 42 such that the opposing end regions extend in opposite directions from the terminal 42. The length of each end region of the first electrical wire lead 46 extending from the terminal 42 may be, for example, 1 inch or more, 2 inches or more, or 3 inches or more. 8, the wire 46, which is the raw material shown in FIG 5, is inserted into each opening 57a / 57b of the terminal 42 until the attachment region 52 of the first electrical lead wire 46 is properly aligned with the attachment surface 54 of the terminal 42. Thus, the terminal 42 is approximately centered between the first end region 47 and the second end region 49 of the first electrical lead wire 46, with the first electrical lead wire 46 extending approximately equal lengths from either side of the terminal 42.

[0086] Figure 9 illustrates another example of a manufacturing step in the process of attaching (e.g., welding) the first electrical wire lead 46 to the terminal 42. Specifically, Figure 9 illustrates the first electrical wire lead 46 after an attachment region 52 of the wire lead 46 has been secured, such as by welding, to an attachment surface 54 of the terminal 42 and the first electrical wire lead 46 has been formed into a curved configuration (having a shape similar to the shape of the first electrical wire lead after it is fully assembled, as shown in Figures 1-4).

[0087] As previously discussed, Figure 9 shows that after welding and bending the first electrical wire lead 46, the first electrical wire lead 46 is positioned through openings 57a and 57b in terminal 42 with opposite end regions 47 / 49 of the first electrical wire lead 46 extending from terminal 42. That is, after welding and bending the electrical wire lead 46 into the configuration shown in Figure 9, the portions of the first electrical wire lead 46 extending away from mounting surface 54 are threaded through openings 57a / 57b, respectively, before forming a curved shape such that first end region 47 is aligned with second end region 49.

[0088] 10-12 and the accompanying description, exemplary manufacturing steps for attaching the second electrical lead wire 44a and / or the third electrical lead wire 44b to the brush 14 are described.

[0089] FIG. 10 illustrates exemplary second and third electrical lead wires 44a / 44b in a pre-formed (e.g., raw material) configuration before the second and / or third electrical lead wires 44a / 44b are formed and attached to the brush 14. As shown in FIG. 10, the pre-formed configuration of the second and third electrical lead wires 44a / 44b is substantially similar to a cylindrical wire having a first end 62a / 62b (described above with reference to FIG. 4) and a second end 64a / 64b (described above with reference to FIG. 4) opposite the first end 62a / 62b. In some examples, the second and third electrical lead wires 44a / 44b are constructed of copper. However, in other examples, the second and third electrical lead wires 44a / 44b may be formed of a variety of different conductive materials. For example, the second and third electrical lead wires 44a / 44b may be constructed of aluminum, silver, etc.

[0090] As further shown in FIG. 10, the second and third electrical lead wires 44a / 44b have a multifilament structure formed from a plurality of individual wires 61 wound together along the longitudinal axis of the electrical lead wires 44a / 44b. The second and third electrical lead wires 44a / 44b shown in FIG. 10 each include eleven individual wires 61 wound together to form the electrical lead wires 44a / 44b. However, the second and third electrical lead wires 44a / 44b may include more or less than eleven individual wires 61 wound together to form the electrical lead wires 44a / 44b. For example, the second and third electrical lead wires 44a / 44b may each be formed from 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 or more individual wires 61. Although not shown, in some examples, the second and third electrical lead wires 44 may be formed from a single solid wire (e.g., the electrical lead wires 44a / 44b may be formed from a single solid cylindrical wire).

[0091] Figure 11 illustrates the second electrical lead wire 44a disposed adjacent to the third electrical lead wire 44b after it has been shaped (e.g., bent, formed, etc.) into the configuration shown in Figure 11. As previously discussed, Figure 11 illustrates that the second electrical lead wire 44a and the third electrical lead wire 44b are formed from a number of individual wires 61 that collectively form the electrical lead wires 44a / 44b.

[0092] The shapes of the second and third electrical lead wires 44a, 44b shown in Figure 11 include shapes substantially similar to the shapes of the second and third electrical lead wires 44a, 44b described above and shown in Figures 1-4 (e.g., the shapes of the second and third electrical lead wires 44a, 44b of the fully assembled system 10 of Figure 1). Figure 11 also shows the second and third electrical lead wires 44a, 44b prior to attachment to the brushes 14.

[0093] As shown in FIG. 11, forming the two separate pre-formed raw materials electrical lead wires 44a / 44b shown in FIG. 10 into a formed configuration of the second electrical lead wire 44a and the third electrical lead wire 44b includes positioning the first end region 62a of the second electrical lead wire 44a adjacent to the first end region 62b of the third electrical lead wire 44b.

[0094] 12 illustrates an example of a manufacturing process in which portions of the second and third electrical wire leads 44a, 44b are secured to the brush 14. Attaching the second and third electrical wire leads 44a, 44b to the brush 14 includes disposing the second and third electrical wire leads 44a, 44b into corresponding holes (e.g., preformed holes, bores and / or openings) in the brush 14. After the second end regions 64a / 64b of each of the second and third wires 44a, 44b are disposed within their respective holes in the brush 14, the holes are filled (e.g., packed) with additional powder material (e.g., carbon powder material), thereby securing the second end regions 64a / 64b of both the second and third electrical wire leads 44a, 44b to the brush 14. The second end regions 64a / 64b of the second and third electrical lead wires 44a, 44b embedded within the brush 14 are shown in dashed lines in Fig. 12. In other words, Fig. 12 shows the brush 14 including two or more individual electrical lead wires extending from the brush 14, with end regions of each of the individual lead wires secured to the brush 14, such as by being embedded in the brush 14. The opposite free end of each lead wire extends from the brush 14 and is secured to another electrical lead wire at a splice region 50. In other examples, only one electrical lead wire (such as the second electrical lead wire 44a) is secured to the brush 14 (e.g., has an end region embedded in a hole in the brush 14) and extends from the brush 14 and is secured to another electrical lead wire (the electrical lead wire extending from the terminal 42) at a splice region 50.

[0095] As also shown in Figure 12, after the second and / or third electrical wire lead 44a, 44b are attached to the brush 14, the first end region 62a of the second and third electrical wire lead 44a is disposed adjacent to the first end region 62b of the third electrical wire lead 44b. As also shown in Figure 12, the ends of the second and third electrical wire lead 44a, 44b are spaced apart from one another where the portions of the second and third electrical wire lead 44a, 44b exit the brush 14. The lateral distance between the spaced apart ends of the second and third electrical wire lead 44a, 44b is shown in Figure 12 as dimension Y. However, as further shown in Figure 12, the ends 62a / 62b of the second and third electrical lead wires 44a / 44b are curved to converge toward the centerline of the brush 14, and the first end regions 62a / 62b of the second and third electrical lead wires 44a / 44b are disposed adjacent to one another. The lateral widthwise distance between the end regions 62a / 62b of the second and third electrical lead wires 44a / 44b where the first end regions 62a / 62b are adjacent to one another is shown in Figure 12 as dimension X. In some instances, dimension Y is greater than dimension X.

[0096] 13-15 and the accompanying description, an exemplary manufacturing process for welding (eg, ultrasonically welding) second electrical lead wire 44a and third electrical lead wire 44b to first electrical lead wire 46 is described.

[0097] An exemplary welding fixture 72 is shown in Figure 13. As shown in Figure 14, the exemplary fixture 72 is configured to secure the first ends of the second and third electrical lead wires 44a and 44b to the first and second ends of the first electrical lead wire 46 while they are welded together. Additionally, the fixture 72 is designed to align the first ends of the second and third electrical lead wires 44a and 44b to the first and second ends of the first electrical lead wire 46 while they are welded together.

[0098] As shown in FIG. 13, the fixture 72 has a first pair of alignment grooves 73a / 73b. As shown in FIG. 14, the first pair of alignment grooves 73a / 73b are designed to position (e.g., align) the first end region 47 and the second end region 49 of the first electrical lead wire 46, respectively, within the cavity of the fixture 72. As further shown in FIG. 13, the fixture 72 also has a second pair of alignment grooves 74a / 74b. As shown in FIG. 14, the first pair of alignment grooves 73a / 73b are designed to position (e.g., align) the first end region 62a of the second electrical lead wire 44a and the first end region 62b of the third electrical lead wire 44b within the cavity of the fixture 72.

[0099] In another example, the fixture 72 has a single alignment groove for side-by-side receiving both the first end region 47 and the second end region 49 of the first electrical lead wire 46 within the cavity of the fixture 72. Additionally, the fixture may include a single alignment groove for side-by-side receiving both the first end region 62a of the second electrical lead wire 44a and the first end region 62b of the third electrical lead wire 44b within the cavity of the fixture 72.

[0100] 13, the fixture 72 has alignment grooves 74a / 74b (or a single alignment groove for the first end regions 62a / 62b of the second and third electrical lead wires 44a / 44b) spaced apart from the first pair of alignment grooves 73a / 73b (or a single alignment groove for the first and second end regions 47 / 49 of the first electrical lead wire 46) to form a weld area 75 within the cavity of the fixture 72. Alignment of the first terminations of the second and third electrical lead wires 44a / 44b with the end of the first electrical lead wire 46 within the weld area 75 prior to welding will be described below with reference to FIG.

[0101] Additionally, the fixture 72 includes one or more clamping members 82a / 82b for clamping or otherwise aligning the terminal ends of the first electrical lead wire 46, the second lead wire 44a, and the third lead wire 44b during the welding process. For example, the fixture 72 includes a first clamping member 82a on a first side of the weld area 75 and a second clamping member 82b on a second side of the weld area 75. The first and second clamping members 82a / 82b are operable toward one another to clamp, compress, or otherwise align the terminal ends of the first electrical lead wire 46, the second lead wire 44a, and the third lead wire 44b between one another within the fixture 72.

[0102] 14 illustrates the first end 62a of the second electrical lead wire 44a, the first end 62b of the third electrical lead wire 44b, and the first and second ends 47 / 49 of the first electrical lead wire 46 positioned within a weld area 75 prior to welding by a welding device 76. Specifically, FIG. 14 illustrates the first end region 62a of the second electrical lead wire 44a positioned within alignment groove 74a of fixture 72, the first end region 62b of the third electrical lead wire 44b positioned within alignment groove 74b of fixture 72, the first end region 47 of the first electrical lead wire 46 positioned within alignment groove 73a of fixture 72, and the second end region 49 of the first electrical lead wire 46 positioned within alignment groove 73b of fixture 72.

[0103] As previously mentioned, in another example, both the first end region 47 and the second end region 49 of the first electrical lead wire 46 are positioned side-by-side within the weld area 75 via a single alignment groove. Additionally, both the first end region 62a of the second electrical lead wire 44a and the first end region 62b of the third electrical lead wire 44b are positioned side-by-side within the weld area 75 via a single alignment groove.

[0104] 14, the first end region 62a of the second electrical lead wire 44a and the first end region 62b of the third electrical lead wire 44b (already secured to the brush 14) are positioned over (i.e., vertically above and overlapping) the first end region 47 and the second end region 49 of the first electrical lead wire 46 (already secured to the terminal 42). In other words, the first end region 47 and the second end region 49 of the first electrical lead wire 46 are positioned below the first end region 62a of the second electrical lead wire 44a and the first end region 62b of the third electrical lead wire 44b. 13, the fixture 72 is designed such that the second pair of alignment grooves 74a / 74b (or a single alignment groove for the end regions 62a / 62b of the second and third electrical lead wires 44a / 44b) is higher than the first pair of alignment grooves 73a / 73b (or a single alignment groove for receiving the end regions 47 / 49 of the first electrical lead wire 46) such that the end regions 47 / 49 of the first electrical lead wire 46 are positioned below the end regions 62a / 62b of the second and third electrical lead wires 44a / 44b. However, in another embodiment, the fixture 72 is designed such that the end regions 47 / 49 of the first electrical lead wire 46 are positioned above the end regions 62a / 62b of the second and third electrical lead wires 44a / 44b.

[0105] Further, as shown in FIG. 14, in some instances, prior to welding, the first end region 62a of the second electrical lead wire 44a and the first end region 62b of the third electrical lead wire 44b overlap (e.g., extend beyond) portions of the first end region 47 and second end region 49 of the first electrical lead wire 46 within the weld area 75. That is, prior to welding, each of the first end region 62a of the second electrical lead wire 44a, the first end region 62b of the third electrical lead wire 44b, the first end region 47 of the first electrical lead wire 46 and the second end region 49 of the first electrical lead wire 46 are positioned within the weld area 75 such that the first end region 62a of the second electrical lead wire 44a and the first end region 62b of the third electrical lead wire 44b extend adjacently along the first end region 47 and second end region 49 of the first electrical lead wire 46.

[0106] 14, prior to welding the second and third electrical lead wires 44a, 44b to the first electrical lead wire 46, the first electrical lead wire 46 is attached (e.g., welded) to the terminal 42 and the second and third electrical lead wires 44a, 44b are attached (e.g., embedded) to the brushes 14. The fixture 42 is designed such that the first electrical lead wire 46 can be welded to the second and / or third electrical lead wires 44a, 44b after the first electrical lead wire 46 is attached to the terminal 42 and the second and / or third electrical lead wires 44a, 44b are attached to the brushes 14.

[0107] After the end regions 62a / 62b of the second and third electrical lead wires 44a / 44b and the end region 47 / 49 of the first electrical lead wire 46 are aligned within the cavity of the fixture 72, the clamping members 82a / 82b are actuated to align the end regions 62a / 62b and the end regions 47 / 49 with one another, such as by clamping, compressing, etc. Then, a welding device 76, such as an ultrasonic welder, is advanced toward the welding area 75 to compress the end regions 62a / 62b of the second and third electrical lead wires 44a / 44b (or the end region 47 / 49 of the first electrical lead wire 46 if the end region 47 / 49 of the first electrical lead wire 46 is located above the end regions 62a / 62b of the second and third electrical lead wires 44a / 44b) to close the top of the cavity of the fixture 72 defining the welding area 75. While compressed together, end regions 62a / 62b and end regions 47 / 49 are welded together by a welding device 76 (e.g., an ultrasonic welder). For example, the welding device 76 vibrates at a high frequency to provide a back and forth motion in a direction parallel to the axes of the end regions of electrical lead wires 44a / 44b / 46 within fixture 72, thereby ultrasonically welding the end regions together.

[0108] 15 illustrates the first end region 62a of the second electrical lead wire 44a, the first end region 62b of the third electrical lead wire 44b, the first end region 47 of the first electrical lead wire 46, and the second end region 49 of the first electrical lead wire 46, being welded together by a welding device 76 (see FIG. 14) to form a weld (e.g., splice) region 50. The weld region 50 may also be referred to as a weld joint, a welded connection, or the like. As can be seen from the assembly illustrated in FIG. 15, in the conductive lead assembly 36, the first electrical lead wire 46 is attached directly to the terminal 42, and the second and third electrical lead wires 44a, 44b are attached directly to the brush 14. Thus, the second and third electrical lead wires 44a, 44b are attached directly to the brush 14, but do not extend to the terminal 42. Similarly, the first electrical wire lead 46 is attached directly to the terminal 42 but does not extend to the brush 14. That is, the second electrical wire lead 44a and / or the third electrical wire lead 44b extend only between the weld splice 50 and the brush 14, and the first electrical wire lead 46 extends only between the weld splice 50 and the terminal 42. It is noted that the assembly shown in FIG. 15 is integrated with the remaining components of the brush holder assembly 12 described above (e.g., the brush holder 16, the lower beam 32, the upper beam 30 and the handle 22).

[0109] Figure 16A is a front view of the assembly shown in Figure 15 and Figure 16B is a side view of the assembly shown in Figure 15. Specifically, Figure 16A shows a front view of the first electrical lead wire 46 and the second and third electrical lead wires 44a / 44b, with the first end region 62a of the second wire 44a, the first end region 62b of the third wire 44b, the first end region 47 of the first wire 46 and the second end region 49 of the first wire 46 terminating in a welded splice region 50.

[0110] Additionally (and again with reference to the discussion of FIG. 12), as shown in FIG. 16A, the two ends of the second and third electrical lead wires 44a, 44b are spaced apart from one another at the points where the end regions exit the brush 14. As discussed above with reference to FIG. 12, the outer width between the spaced apart ends of the second and third electrical lead wires 44a, 44b is shown in FIG. 16A as dimension Y (which is the same as dimension Y shown in FIG. 12).

[0111] Additionally, as can be seen in FIG. 16A , the outer widthwise dimensions of the outer edges of first end region 47 of first electrical lead wire 46, second end region 49 of first electrical lead wire 46, first end region 62a of second electrical lead wire 44a, first end region 62b of third electrical lead wire 44b and weld region 50 are all less than dimension Y. The width of the welded area 50 (and the widths of the first end region 47 of the first wire 46, the second end region 49 of the first wire 46, the first end region 62a of the second wire 44a, and the first end region 62b of the third wire 44b that terminate in the welded area 50) being smaller than the width Y prevents portions of the first electrical lead wire 46, the second electrical lead wire 44a, and the third electrical lead wire 42b from getting caught on the brush holder 16 (FIG. 1) or an edge of the brush holder 16 as the brush 14 translates within the interior space of the side wall of the brush holder 16 (resulting in pulling the first wire 46, the second wire 44a, and the third wire 44b) toward the surface 18 (FIG. 1) of the rotating part 20 (FIG. 1) of the electrical device.

[0112] 16B, the first end regions 62a / 62b of the second and third electrical lead wires 44a / 44b are disposed closer to the front face of the brush 14 than the end regions 47 / 49 of the first electrical lead wire 46, such that the terminal end of the first electrical lead wire 46 (facing or pointing toward the brush 14) is inhibited from catching on the top edge of the brush holder 16 as the weld splice 50 moves inwardly of the brush holder 16 as the brush 14 wears and reduces in length. Thus, the end regions 47 / 49 of the first electrical lead wire 46 are disposed closer to the longitudinal central axis of the brush 14 than the first end regions 62a / 62b of the second and third electrical lead wires 44a / 44b, which are closer to the front edge of the brush 14. That is, the end regions of the wires 44a / 44b / 46 are positioned so that the movement of the welded joint 50 into the interior of the brush holder 16 is not hindered by the terminal end of the first lead wire 46, and at the same time, the end regions 62a / 62b of the second lead wire 44a and the third lead wire 44b are positioned so that the welded joint 50 can be guided into the interior of the brush holder 16.

[0113] 15, the above-described positioning of the end regions of wires 44a / 44b relative to the terminal end of first wire lead 46 prior to welding (the end regions of wires 44a / 44b are positioned closer to the leading edge of the brush than the terminal end of first wire lead 46 as shown in FIG. 14) creates a weld splice 50 having a downward shelf (e.g., lip, edge, surface, etc.) against the top surface of brush 14. However, the shelf 63 is located inward toward the centerline of brush 14, thereby preventing shelf 63 from catching on the top edge of brush holder 16 as brush 14 moves inwardly into brush holder 16 as brush 14 wears and shortens. The downward shelf 63 of weld splice 50 is formed by the terminal end of first wire lead 46. 15, the terminations of the second and third electrical lead wires 44a / 44b also form a ledge 65 (e.g., lip, edge, face, etc.) of the weld splice 50 that faces upwardly, away from the brush 14. The orientation of the upward ledge 65 does not impede movement of the weld splice into the interior of the brush holder 16.

[0114] Figure 17 illustrates an example brush-holder assembly 12 described herein positioned along a conductive surface 18 of a rotating part 20 of an electrical device. Figure 17 illustrates a brush 14 (described above with respect to Figure 1) positioned within a brush holder 16 with a lower surface 26 of the brush 14 engaging the conductive surface 18 of the rotating part 20. Continued contact of the lower surface 26 with the conductive surface 18 of the rotating part 20 causes wear of the lower surface 26, which in turn causes an upper surface 24 of the brush 14 to translate linearly within the brush holder 16 towards the conductive surface 18.

[0115] In some instances, it may be desirable to monitor the distance that the top surface 24 translates within the brush holder 16 to determine the degree of wear on the brush 14. For example, it may be desirable to monitor the distance that the top surface 24 of the brush 14 travels relative to the top edge 78 of the brush holder 16 or other fixed reference point that is located a fixed distance from the conductive surface 18. The distance that the top surface 24 travels relative to the top edge 78 of the brush holder 16 (or other fixed reference point) represents the amount of brush material that has been removed from the bottom surface 26 of the brush 14 (i.e., how much the brush 14 has worn or shortened during use).

[0116] In some instances, it may be difficult to monitor the distance that the top surface 24 has moved relative to the top edge 78 of the brush holder 16. Thus, in some instances, another component of the brush holder assembly 12 that is located a fixed distance from the conductive surface 18 is used as a reference point to determine the distance that the top surface 24 of the brush 14 has moved relative to the top edge 78 of the brush holder 16.

[0117] As shown in FIG. 17, in some instances, the band 48 (attached to the first electrical lead wire 46 (or the second electrical lead wire 44a and / or the third electrical lead wire 44b)) is used as a reference point to determine the distance the top surface 24 of the brush 14 has traveled relative to the top edge 78 of the brush holder 16. For example, in FIG. 17, the initial distance of the band 48 from the top edge 78 at a first time is shown as dimension Z. As the bottom surface 26 of the brush 14 wears, the distance Z decreases. By monitoring the change in distance Z, the amount of brush material removed from the bottom surface 26 of the brush 14 can be determined, which in turn can determine the degree of wear and / or reduction in length of the brush 14 during use. If the wear of the brush 14 exceeds a threshold amount, the brush 14, along with the terminals 42 and associated conductive electrical lead assembly 36, can be removed and replaced with a new brush assembly 45.

[0118] Similarly, as shown in FIG. 17, in some instances, the weld or splice area 50 is used as a reference point to determine the distance the top surface 24 of the brush 14 has moved relative to the top edge 78 of the brush holder 16. For example, in FIG. 17, the initial distance of the weld or splice area 50 from the top edge 78 at a first time is shown as dimension W. As the bottom surface 26 of the brush 14 wears, the distance W decreases. By monitoring the change in distance W, the amount of brush material removed from the bottom surface 26 of the brush 14 can be determined, which in turn can determine the degree of wear and reduction in length of the brush 14 during use. If the wear of the brush 14 exceeds a threshold amount, the brush 14, along with the terminals 42 and associated conductive electrical lead assembly 36, can be removed and replaced with a new brush assembly 45.

[0119] In some examples, the brush holder assembly 12 described herein includes an alternative conductive wire assembly that functions similarly to the conductive wire assembly 36, but has one or more parts and / or manufacturing methods that differ from the conductive wire assembly 36. For example, FIG. 18 illustrates various parts of another exemplary conductive wire assembly 136 that engages and extends from the brush 114. The brush 114 is similar in shape and function to the brush 14 described herein.

[0120] 18 illustrates an exemplary manufacturing process in which the first electrical wire lead 146 and the second electrical wire lead 144 are pre-secured to the brush 114. As shown in FIG. 18, the first electrical wire lead 146 has a first end region 147, a second end region 149, and a middle region extending between the first end region 147 and the second end region 149. The second electrical wire lead 144 has a first end region 164 and a second end region 165. Additionally, as shown in FIG. 18, the first electrical wire lead 146 is longer than the second electrical wire lead 144 prior to being welded together (which will occur in a subsequent manufacturing process). That is, the first electrical wire lead 146 has a first length extending from the top surface of the carbon brush 114 to a free end of the first electrical wire lead 146 at the first end region 147, and the second electrical wire lead 144 has a second length extending from the top surface of the carbon brush 114 to a free end of the second electrical wire lead 144 at the first end region 164. The first length is greater than the second length.

[0121] The first electrical wire lead 146 (e.g., second end region 149 of first electrical wire lead 146) and / or the second electrical wire lead 144 (e.g., second end region 165 of second electrical wire lead 144) are secured to the carbon brush 114 in a desired manner. Attaching the first electrical wire lead 146 and / or the second electrical wire lead 144 to the brush 114 includes placing the first electrical wire lead 146 and the second electrical wire lead 144, respectively, within corresponding holes (e.g., preformed holes, bores and / or openings) in the brush 114. After the second end region 149 of the first electrical lead wire 146 and the second end region 165 of the second electrical lead wire 144 are disposed within their respective holes in the brush 114, the holes are filled (e.g., packed) with additional powder material (e.g., carbon powder material) to secure the second end regions 149 / 165 of both the first electrical lead wire 146 and the second electrical lead wire 144 to the brush 114. Similar to that shown in FIG. 12, the second end regions 149 / 165 of the first electrical lead wire 146 and the second electrical lead wire 144 embedded within the brush 114 are shown in FIG. 18 with dashed lines. In other words, FIG. 18 shows the brush 114 to include two or more individual electrical lead wires extending therefrom, with the end regions of each of the individual lead wires secured to the brush 114, such as by being embedded in the brush 114. As described below, the opposite free ends 147 / 164 of the first and second lead wires 146, 144 extend from the brush 114 and are secured to one another at a splice region 150 (FIG. 21).

[0122] Similar to FIG. 12, as shown in FIG. 18, the second ends 149 / 165 of the first electrical lead wire 146 and the second electrical lead wire 144 are spaced apart from each other where the portions of the first electrical lead wire 146 and the second electrical lead wire 144 exit the brush 114.

[0123] 18, prior to welding the first end region 147 of the first electrical wire lead 146 to the first end region 164 of the second electrical wire lead 144, the terminal 142 is attached (e.g., welded) to the intermediate region of the first electrical wire lead 146 at a location between the first end region 147 and the second end region 149, with the first end region 147 of the first electrical wire lead 146 extending from a first side of the terminal 142 and the second end region 149 of the first electrical wire lead 146 extending from an opposite second side of the terminal 142. The shape and function of the terminal 142 are similar to the terminal 42 described herein. Furthermore, as shown in FIG. 18, in some instances, the terminal 142 is welded along the first electrical wire lead 146 at a location closer to the first end region 147 than the second end region 149 of the first electrical wire lead 146 (which is embedded in the brush 114). That is, the terminal 142 is welded to an intermediate region of the first electrical lead wire 146 such that the length of the first electrical lead wire 146 extending between the terminal 142 and the carbon brush 114 is longer than the length of the first electrical lead wire 146 extending between the terminal 142 and the free end (first end region 147) of the first electrical lead wire 146.

[0124] 18 is attached to first electrical wire lead 146 after second end region 149 of first electrical wire lead 146 has been inserted and attached to brush 114 and before first end region 147 of first electrical wire lead 146 is welded to first end region 164 of second electrical wire lead 144. For example, prior to forming the configuration shown in FIG. 18, first electrical wire lead 146 is inserted into an opening in terminal 142 (e.g., similar to openings 57a / 57b of terminal 42) and then terminal 142 is properly aligned along a mid-region of first electrical wire lead 146. For example, as shown in FIG. 18 , the terminal 142 is generally positioned closer to the first end region 147 of the first electrical lead wire 146, with a shorter length of the first electrical lead wire 146 extending from the side of the terminal 142 away from the brush 114 and a longer length of the first electrical lead wire 146 extending from the side of the terminal 142 closer to the brush 114.

[0125] After the terminal 142 is positioned at a desired location along the lead wire 146, the first electrical lead wire 146 is secured, such as by welding, to the terminal 142. Attachment of the terminal 142 to the first lead wire 146 may be by a process similar to that described above with respect to attachment of the terminal 42 and lead wire 46 of Figures 8 and 9. Securing the terminal 142 to the first lead wire 146, such as by welding, may be performed before or after attachment of the first lead wire 146 and / or the second lead wire 144 to the brush 114.

[0126] 19 illustrates another example of a manufacturing process for forming the conductive electrical assembly 136. Specifically, in the manufacturing process illustrated in FIG. 19, the first electrical wire lead 146 is bent such that the first end region 147 of the first electrical wire lead 146 is disposed adjacent the first end region 164 of the second electrical wire lead 144, and the free end of the first electrical wire lead 146 is adjacent the free end of the second electrical wire lead 144. As illustrated in FIG. 19, the first electrical wire lead 146 is bent to form a loop. As illustrated in FIG. 19, when the first electrical wire lead 146 is formed into a loop, the terminal 142 is disposed to be generally aligned with the apex of the loop formed on the opposite side of the brush 114.

[0127] Also, as shown in Figure 19, portions of both the first electrical wire lead 146 and the second electrical wire lead 144 are adjacent to one another (e.g., the free ends of the first and second electrical wire leads 146 / 144). For example, as shown in Figure 19, the first electrical wire lead 146 and the second electrical wire lead 144 are curved to converge toward the centerline of the brush 114, such that the first electrical wire lead 146 and the second electrical wire lead 144 are positioned next to one another prior to being welded together.

[0128] 20 and 21 show examples of manufacturing processes similar to those described with reference to FIGS. 14 and 15. For example, as shown in FIG. 20, the first end region 147 of the first electrical lead wire 146 (including the free end of the first electrical lead wire 146) and the first end region 164 of the second electrical lead wire 144 (including the free end of the second electrical lead wire 144) are positioned in the welding area prior to welding with the welding device 76. In some examples, the intermediate region of the first electrical lead wire 146 is juxtaposed with the first end region 147 of the first electrical lead wire 144 and the first end region 164 of the second electrical lead wire 146 in the welding area. For example, FIG. 20 shows the first end region 147 of the first electrical lead wire 146, the first end region 164 of the second electrical lead wire 144, and the intermediate region of the first electrical lead wire 146 held in a pre-welding position by a fixture 172. The fasteners 172 are similar in form and function to the fasteners 72 described herein.

[0129] 20, the first end region 164 of the second electrical lead wire 144 (the second end region 165 of the second electrical lead wire 144 is already secured to the brush 114) is overlapped (i.e., vertically above and overlapping) the first end region 147 of the first electrical lead wire 146 (the second end region 149 of the first electrical lead wire 146 is already secured to the brush 114). In such a configuration, the first end region 164 of the second electrical lead wire 144 is disposed above the first end region 147 of the first electrical lead wire 146. In other words, the first end region 147 of the first electrical lead wire 146 is located below the first end region 164 of the second electrical lead wire 144. Similar to what is described above with respect to fixture 72, fixture 172 is designed to position first end region 147 of first electrical wire lead 146 under second end region 164 of second electrical wire lead 144 before the lead wires are welded together. Thus, as shown in FIG. 20 , in some instances, first end region 147 of first electrical wire lead 146 overlaps (e.g., extends beyond) a portion of first end region 164 of second electrical wire lead within the weld zone of welding apparatus 76 prior to welding.

[0130] Further, as shown in FIG. 20 , first electrical lead wire 146 is attached (e.g., welded) to terminal 142 (above) and first electrical lead wire 146 and second electrical lead wire 144 are attached (e.g., embedded) to brush 114 prior to welding first end region 147 of first electrical lead wire 146 to first end region 164 of second electrical lead wire 144 and, optionally, welding an intermediate region of first electrical lead wire 146 to first end regions 147 / 164 of first and second electrical lead wires 146 / 144. The fixture 172 is designed to allow the first end region 147 of the first electrical lead wire 146, the first end region 164 of the second electrical lead wire 144 and / or the intermediate region of the first electrical lead wire 146 to be welded together after the first electrical lead wire 146 is attached to the terminal 142 and the first electrical lead wire 146 and / or the second electrical lead wire 144 are attached to the brush 114.

[0131] After the first end region 147 of the first electrical lead wire 146, the first end region 164 of the second electrical lead wire 144 and / or the mid-region of the first electrical lead wire 146 are aligned within the fixture 172, a welding device 76, such as an ultrasonic welder, advances toward the first end region 147 of the first electrical lead wire 146, the first end region 164 of the second electrical lead wire 144 and / or the mid-region of the first electrical lead wire 146 and ultrasonically welds the end regions 147 / 164 together to form a splice joint. During the welding process, the first end region 147 of the first electrical lead wire 146 is welded to the first end region 164 of the second electrical lead wire 144. Further, in some examples, a portion of the mid-region of the first electrical lead wire 146 juxtaposed with the first end regions 147 / 164 of the first and second electrical lead wires 146 / 144 is welded to the first end region 147 of the first electrical lead wire 146 and / or the first end region 164 of the second electrical lead wire 144. The process of welding the first end region 147 of the first electrical lead wire 146, the first end region 164 of the second electrical lead wire 144 and / or the mid-region of the first electrical lead wire 146 is similar to the welding process described with reference to FIGS.

[0132] 21 illustrates first end region 147 of first electrical lead wire 146, first end region 164 of second electrical lead wire 144, and the intermediate region of first electrical lead wire 146 all being welded together by welding device 76 (shown in FIG. 20) to form a splice joint 150 (e.g., splice connection, welded connection) along conductive lead assembly 136. Splice joint 150, also referred to as a weld joint, welded region, welded connection, etc., is obtained by splicing together (e.g., ultrasonically welding) first end region 147 of first electrical lead wire 146, first end region 164 of second electrical lead wire 144, and optionally a portion of the intermediate region of first electrical lead wire 146. It should be noted that in some instances, the weld or splice region 150 is formed solely by welding the first end region 147 of the first electrical lead wire 146 to the first end region 164 of the second electrical lead wire 144. In the lead assembly 136 shown in FIG. 21, the first electrical lead wire 146 is attached directly to the terminal 142, a first portion 152 of the first electrical lead wire 146 extends continuously from the terminal 142 through the weld or splice joint or region 150 to the brush 114, and a second portion 154 of the first electrical lead wire 146 extends from the terminal 142 and terminates at the weld or splice joint or region 150. The second electrical lead wire 144 is attached directly to the brush 114 and extends from the brush 114 and terminates at the weld or splice joint or region 150. Thus, a first portion 152 of the first electrical wire lead 146 is attached directly to the brush 114 and extends through the splice joint 150 to the terminal 142, while a second portion 154 of the first electrical wire lead 146 is attached directly to the terminal 142 but does not extend to the brush 114 (i.e., terminates at the splice joint 150). Additionally, the second electrical wire lead 144 extends only between the weld splice 150 and the brush 114.

[0133] 21, some examples of the conductive lead assembly 136 include wear marks 151 on one or more surfaces of the weld splice 150. The wear marks 151 can be etched, stamped, inked, or otherwise applied or formed on the weld splice 150. The wear marks 151 are positioned a predetermined distance from the top surface of the brush 114. For example, the wear marks 151 are positioned approximately 1.5 inches from the top surface of the brush 114 with the conductive lead assembly 136 extending away from the top surface of the brush 114. As will be described in more detail below, the wear marks 151 can provide a visual indication of the amount of wear or reduction in the brush 114 during use.

[0134] It should be noted that the conductive lead assembly 136 shown in FIG. 21 is integrated with the remaining components of the brush holder assembly 12 (eg, the brush holder 16, the lower beam 32, the upper beam 30 and the handle 22).

[0135] FIGURE 22 illustrates an exemplary conductive lead assembly 136 integrated with a brush-holder assembly 12 that is positioned along a conductive surface 18 of a rotating component 20 of an electrical device. For example, FIGURE 22 illustrates a brush 114 (similar to that previously described with respect to FIGURE 1) positioned within the brush holder 16 with a lower surface 126 of the brush 114 engaging the conductive surface 18 of the rotating component 20. Continued contact of the lower surface 126 with the conductive surface 18 of the rotating component 20 causes wear of the lower surface 126, which in turn causes an upper surface 124 of the brush 114 to translate linearly within the brush holder 16 towards the conductive surface 18.

[0136] As described herein, it may be desirable to monitor the distance that the top surface 124 of the brush 114 translates within the brush holder 16 to determine the degree of wear and reduction in length of the brush 114. For example, it may be desirable to monitor the distance that the top surface 124 of the brush 114 travels relative to the top edge 78 of the brush holder 16 or other reference point that is located a fixed distance from the conductive surface 18. The distance that the top surface 124 travels relative to the top edge 78 (or other fixed reference point) of the brush holder 16 represents the amount of brush material that has been removed from the bottom surface 126 of the brush 114 (i.e., how much the brush 114 has worn or shortened during use).

[0137] As shown in FIG. 22, in some instances, wear marks 151 along the seam area 150 are used as a reference point to determine the distance the top surface 124 of the brush 114 has traveled relative to the top edge 78 of the brush holder 16. For example, FIG. 22 shows the initial distance of the wear mark 151 from the top edge 78 at a first time as dimension A. As the bottom surface 126 of the brush 114 wears, the distance A decreases. By monitoring the change in distance A, the amount of brush material removed from the bottom surface 126 of the brush 114 can be determined, which in turn can determine the degree of wear and reduction in length of the brush 114 during use. If the wear of the brush 114 exceeds a threshold amount, the brush 114, along with the terminals 142 and associated conductive electrical lead assemblies 136, can be removed and replaced with a new brush assembly.

[0138] Those skilled in the art will recognize that aspects of the present disclosure may be embodied in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, changes in form and detail may be made without departing from the scope and spirit of the present disclosure as set forth in the appended claims.

Claims

1. 1. A brush assembly comprising: a carbon brush having an upper surface and a lower surface; a first lead wire including a first end region, a second end region, and an intermediate region disposed between the first end region and the second end region of the first lead wire, the first lead wire extending continuously from the first end region to the second end region; a second lead wire, the second lead wire including a first end region and a second end region; a conductive terminal attached to the first lead wire, a first end region and a second end region of the first lead wire extending away from the conductive terminal; the first lead wire is joined to the second lead wire at a splice joint, the splice joint being located between the conductive terminal and the carbon brush and spaced apart from both the conductive terminal and the carbon brush; a second end region of the first lead wire and a second end region of the second lead wire are fixed to a carbon brush; A brush assembly, wherein the splice joint is formed by welding a portion of an intermediate region of the first lead wire to both a first end region of the first lead wire and a first end region of the second lead wire.

2. 2. The brush assembly of claim 1, wherein the first lead wire extends from the conductive terminal to the splice joint, and the second lead wire is secured to the carbon brush and extends from the carbon brush to the splice joint.

3. A brush assembly as described in claim 1, wherein the conductive terminal is fixed to the intermediate region of the first lead wire.

4. 2. The brush assembly of claim 1, wherein the splice joint has a wear mark, the wear mark being used as a reference point for determining wear loss of the carbon brush.

5. the conductive terminal having an inner core layer positioned between a first conductive metal layer and a second conductive metal layer; the inner core layer comprises steel; 5. A brush assembly as described in any one of claims 1 to 4, wherein the first conductive metal layer, the second conductive metal layer, or both the first conductive metal layer and the second conductive metal layer comprise copper.

6. The brush assembly according to claim 1, further comprising: A brush holder having a brush housing and a beam secured to the brush housing, the carbon brush being slidably disposed within the brush housing and the conductive terminal being removably attached to the beam of the brush holder. The brush assembly comprises:

7. 2. The brush assembly of claim 1, wherein the first lead wire is longer than the second lead wire, and the conductive terminal is secured along the intermediate region of the first lead wire at a location closer to the first end region of the first lead wire than to the second end region of the first lead wire.

8. The brush assembly of claim 1, The conductive terminal has an inner core layer positioned between a first conductive metal layer and a second conductive metal layer.

9. 9. The brush assembly of claim 8, further comprising a conductive lead assembly welded directly to the first conductive metal layer of the conductive terminal.

10. the inner core layer comprises steel; 10. The brush assembly of claim 8 or 9, wherein the first conductive metal layer, the second conductive metal layer, or both the first and second conductive metal layers comprise copper.

11. 1. A method of manufacturing a brush assembly, comprising: welding a first end region and a middle region of a first lead wire to a first end region of a second lead wire, the middle region being disposed between the first end region and the second end region of the first lead wire, the first lead wire extending continuously from the first end region to the second end region of the first lead wire, and the first lead wire being pre-fixed to a conductive terminal and the second lead wire being pre-fixed to a carbon brush prior to the welding step; the welding forms a splice joint between the first lead wire and the second lead wire, the splice joint being between the carbon brush and the conductive terminal and spaced apart from the carbon brush and the conductive terminal.

12. The method of claim 11 , wherein the conductive terminal is secured along the intermediate region of the first lead wire.

13. 1. A brush assembly comprising: Carbon brushes and a first lead wire fixed to and extending from the carbon brush; a second lead wire fixed to and extending from the carbon brush; a first end region and an intermediate region of the first lead wire are secured to the first end region of the second lead wire at the splice joint by looping a portion of the first lead wire extending from the splice joint; a conductive terminal secured to a looped portion of the first lead wire between the first end region and an intermediate region; The splice joint is disposed spaced apart from and between the carbon brush and the conductive terminal.

14. 14. The brush assembly of claim 13, A brush assembly, wherein the first end region and an intermediate region of the first lead wire are ultrasonically welded to the first end region of the second lead wire at the splice joint.

15. 14. The brush assembly of claim 13, the first lead wire is longer than the second lead wire; the conductive terminal is secured along the first lead wire at a location closer to the first end region of the first lead wire than the carbon brush.

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