Brush holder assembly

Abstract

To provide a brush and a brush holder assembly for use in electrical equipment and / or slip ring assembly.SOLUTION: A brush assembly 45 includes a carbon brush 14, a first lead wire 46, a second lead wire 44a, a third lead wire 44b, and a terminal 42. The first end region of the first lead wire 46 is joined to the first end region of the second lead wire 44a at a splice joint 50, and the second end region of the first lead wire 46 is joined to the first end region of the third lead wire 44b at the splice joint 50. The second end region of the second lead wire 44a and the second end region of the third lead wire 44b are joined to the carbon brush 14. The splice joint 50 is located between the terminal 42 and the carbon brush 14, and is spaced apart from both the terminal 42 and the carbon brush 14.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure generally relates to brushes and brush holder assemblies that can 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 movable surface.

Background Art

[0002] The purpose of the brush in electrical equipment is to conduct current from a fixed contact to a movable 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 in sliding connection applications such as slip ring assemblies on rotating devices such as rotary cranes and linear slide connections of monorails. The brushes of many electrical devices are blocks or other structures made of conductive materials such as graphite, carbon graphite, electrographite, and metal graphite, and are configured to contact a conductive surface or a surface through which current passes. A conductive lead wire or shunt extends from the brush to form an electrical path to the brush of another conductive member and / or an electrical path from the brush.

[0003] In some designs, a brush holder in the form of a brush housing or other types of brush holders are used to support the brush that contacts the movable contact surface of the electrical equipment during operation. The brush and the brush housing are designed to allow the brush to slide within the brush housing and to continue the contact between the movable contact surface contacted by the brush and the brush. In this specification, the brush, the brush holder, related components, and the manufacturing methods of the brush, the brush holder, and related components will be described.

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a brush holder assembly.

Means for Solving the Problems

[0005] The first example is a brush assembly comprising 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 has a splice that is located between the conductive terminal and the carbon brush and is spaced apart from both the conductive terminal and the carbon brush.

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

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

[0008] Additionally or alternatively, the splice is formed by welding the first end region of the first lead wire to the 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 fixed to the intermediate region of the first lead wire. Additionally or alternatively, the second end region of the first lead wire is embedded in the upper surface of the carbon brush at a first position, and the second end region of the second lead wire is embedded in the upper surface of the carbon brush at a second position, with the first position spaced apart from the second position.

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

[0011] Additionally or alternatively, the joint surfaces may have wear marks, which are used as reference points for determining the reduction in carbon brush wear. Additionally or alternatively, the splice 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 the first end region and the second end region of the first lead wire, and the intermediate portion of the first lead wire is fixed to a conductive terminal.

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

[0014] Additionally or alternatively, the splice 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 and the first end region of the third lead wire.

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

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

[0017] Additionally or alternatively, the first conductive metal layer, the second conductive metal layer, or both the first and second conductive metal layers contain copper. Another example is a method for manufacturing a brush assembly. This method involves welding the first end region of a first lead wire to the first end region of a second lead wire. Prior to the welding process, the first lead wire is pre-fixed to a conductive terminal and the second lead wire is pre-fixed to a carbon brush. The welding creates a splice between the first lead wire and the second lead wire. The splice is located between the carbon brush and the conductive terminal, spaced apart from both the carbon brush and the conductive terminal.

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

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

[0020] Alternatively or in addition, the first lead wire is longer than the second lead wire, and the conductive terminal is fixed 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] Alternatively or in addition, the welding process includes welding a part 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 butt joint.

[0022] Alternatively or in addition, before the welding process, 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 arranged 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] Alternatively or in addition, the method includes forming abrasion marks on the surface of the butt joint. Alternatively or in addition, the welding process further includes welding the second end region of the first lead wire to the first end region of a third lead wire at the butt joint.

[0024] Alternatively or in addition, before the welding process, the method includes 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. 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. [[ID= nineteen]]

[0025] Additionally or alternatively, the method includes welding a first end region of a third lead wire to a first end region of the first lead wire and a first end region of the second lead wire at the splice joint. The third lead wire is pre-fixed to the carbon brush before the welding process.

[0026] Another example is a brush holder assembly for positioning 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 fixed 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 fixed to the conductive terminal and a second lead wire fixed to the carbon brush and extending from the carbon brush. A first end region of the first lead wire is fixed to a first end region of the second lead wire at the splice joint. The splice joint is provided at a position spaced apart from the carbon brush and the conductive terminal between 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 the splice joint. 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, and the conductive terminal is fixed 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 fixed along the 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, the second end region of the first lead wire is embedded in a first position on the upper surface of the brush, and the second end region of the second lead wire is embedded in a second position on the upper surface of the brush. The first position is spaced apart from the second position.

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

[0031] Additionally or alternatively, the splice 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 has an inner core layer located between a first conductive metal layer and a second conductive metal layer. Additionally or alternatively, the joint surfaces may have wear marks, which are used as reference points for determining the reduction in carbon brush wear.

[0033] Another example of a brush assembly comprises a carbon brush having an upper and 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] Alternatively, a conductive lead assembly is welded directly to the first conductive metal layer of the conductive terminal. Additionally or alternatively, the inner core layer contains steel.

[0035] Additionally or alternatively, the first conductive metal layer, the second conductive metal layer, or both the first and second conductive metal layers contain copper. Additionally or alternatively, the conductive lead assembly has a splice 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 has a first lead wire connected to a second lead wire at a splice joint. Additionally or alternatively, a first lead wire is fixed to a conductive terminal and extends from the conductive terminal to a joint, and a second lead wire is fixed to a carbon brush and extends from the carbon brush to a joint.

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

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

[0039] Additionally or alternatively, the splice 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 any embodiment or any practice of the present disclosure. These embodiments are illustrated in detail by the following drawings and detailed description.

[0041] Aspects of this disclosure will be better understood by considering the following detailed description of various embodiments together with the accompanying drawings. [Brief explanation of the drawing]

[0042] [Figure 1] An illustrative diagram of an exemplary brush holder assembly positioned adjacent to a rotating component of an electrical device. [Figure 2] Figure 1 shows an exploded view of the components of an exemplary brush holder assembly. [Figure 3] Figure 1 shows an example brush assembly of a brush holder assembly. [Figure 4] Figure 3 shows an exploded view of a brush assembly, illustrating an exemplary brush holder assembly. [Figure 5] Figure 1 shows the lead wires of an exemplary brush holder assembly. [Figure 6] Figure 5 shows lead wires molded for use in a brush holder assembly. [Figure 7] Figure 1 shows the terminals of an exemplary brush holder assembly. [Figure 8] This diagram shows the connection of the terminals in Figure 7 to the lead wires in Figure 5 or 6, and illustrates the state before they are fixed to the lead segments during the manufacturing process. [Figure 9] This diagram shows the state after the terminals and lead wires shown in Figure 8 have been fixed to each other. [Figure 10] Figure 1 shows an example of a brush holder assembly with additional lead wires. [Figure 11] Figure 10 shows a part molded for use in a brush holder assembly. [Figure 12] Figure 10 shows the lead wires after they have been attached to the brush of the exemplary brush holder assembly in Figure 1. [Figure 13] Figure 1 shows an example of a fastener for securing the ends of the lead wires together in an exemplary brush holder assembly. [Figure 14]Figure 13 shows the lead wires of an exemplary brush holder assembly, positioned along an exemplary fastener, before they are fixed together. [Figure 15] Figure 14 shows the state of the brush holder assembly after the lead wires have been fixed together. [Figure 16A] Front view of an exemplary brush holder brush assembly shown in Figure 15. [Figure 16B] A side view of an exemplary brush holder brush assembly shown in Figure 15. [Figure 17] An illustrative diagram of an exemplary brush holder assembly positioned adjacent to a rotating component of an electrical device. [Figure 18] A diagram showing terminals attached to the lead wires of another exemplary brush holder assembly. [Figure 19] Figure 18 shows the lead wires of an exemplary brush holder assembly before they are fixed together. [Figure 20] Figure 19 shows the lead wires of an exemplary brush holder assembly positioned along an exemplary fastener before being fixed together. [Figure 21] Figure 20 shows the state of the brush holder assembly after the lead wires have been fixed together. [Figure 22] An illustrative diagram of an exemplary brush holder assembly shown in Figure 21, positioned adjacent to a rotating component of an electrical device. [Modes for carrying out the invention]

[0043] While various modifications and alternative forms are possible for the embodiments of this disclosure, certain examples are shown in the drawings and described in detail. However, the embodiments of this disclosure are not limited to the specific embodiments described. The present invention encompasses all modifications, equivalents, and alternatives that fall within the spirit and scope of the invention.

[0044] With respect to the terms defined below, unless otherwise defined in the claims or herein, the following definitions shall apply. In this specification, all numerical values, whether expressly indicated or not, are considered to be modified by the word “approximately.” The word “approximately” generally refers to a range of numerical values ​​that a person skilled in the art would consider equivalent to (i.e., having the same function or result as) the stated value. In many cases, the word “approximately” refers to a number rounded to the nearest significant figure.

[0045] Numerical ranges specified by upper and lower limits include all numbers within that range (for example, 1-5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5). While several optimal dimensions, ranges, and / or numerical values ​​for various parts, features, and / or specifications are disclosed, a person skilled in the art will understand from the disclosures herein that preferred dimensions, ranges, and / or numerical values ​​may differ from those explicitly stated herein.

[0046] In this specification and the attached claims, the singular forms “one” and “it” include multiple subjects unless otherwise specified. In this specification and the attached claims, the term “or” means “and / or” unless otherwise specified.

[0047] In the following description, references are made to the figures, where similar parts in different figures are denoted by the same reference numerals. The detailed description and drawings of the disclosure illustrate exemplary embodiments and do not limit the scope of the invention. The drawings are not necessarily to scale. The exemplary embodiments are intended solely for illustrative purposes of the invention. Unless otherwise specified, certain features of the exemplary embodiments can be incorporated into other embodiments.

[0048] Figure 1 shows an exemplary system 10 with a brush holder assembly 12. In some respects, the brush holder assembly 12 is similar to the brush holder assembly described in U.S. Patent No. 7,034430, entitled “Brush Holder Apparatus, Brush Assembly and Method,” which is incorporated herein by reference in its entirety. However, the exemplary system 10 has features as described herein.

[0049] As shown in Figure 1, the brush holder assembly 12 has a brush holder 16 in which carbon brushes 14 are arranged. In some examples, Figure 1 shows that the brush holder 16 has multiple guide surfaces that guide the linear or longitudinal movement of the brushes 14 toward the conductive surface 18 of the rotating part 20, by surrounding one or more sides of the brushes 14 with the brush holder 16 (e.g., brush housing). In other words, as the brushes 14 wear down, they move linearly within the opening defined by the multiple guide surfaces of the brush holder 16. In some embodiments, the brush holder 16 is not box-shaped but has one or more guide surfaces such as grooves, posts, or supports that abut against and / or surround one or more sides of the brushes 14, and / or extend into or penetrate the brushes 14 or a portion thereof, in order to guide the linear or longitudinal movement of the brushes 14.

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

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

[0052] As shown in Figure 1, the brush assembly 12 has an upper beam 30 and a lower beam 32 that are hinged or rotatably coupled to each other. When the upper beam 30 and the lower beam 32 are aligned with each other (for example, 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 brush 14 is adjacent to or in direct electrical contact with the conductive surface 18.

[0053] As further shown in Figure 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 related structures and functions are described in U.S. Patent Application Publication No. 2020 / 0112133 and U.S. Patent Application Publication No. 2020 / 0112223, and these disclosures are incorporated herein by reference. The spacer 40 is attached to the first end face 24 of the brush 14. Furthermore, as shown in Figure 1, the wear condition monitor 38 is connected to a spring 41. In some examples, a portion of the spring 41 is coiled around a portion of the wear condition monitor 38, with the elongated portion of the spring 41 extending from the coiled portion. Thus, the wear condition monitor 38 is located within the coiled portion of the spring 41.

[0054] Thus, in some examples, the wear condition monitor 38 may be mounted adjacent to the surface of the spring 41, or it may be mounted inside the spring 41, for example, within the coiled portion of the spring 41. The spring 41 may be a constant-force spring that applies tension to the brush 14, the wear condition monitor 38, or both the brush 14 and the wear condition monitor 38, thereby biasing the brush 14 toward and into contact with the conductive surface 18 of the rotating part 20. In other words, the spring 41 has a coiled portion designed to provide a force that engages the brush 14 with the rotating part 20 of an electrical device such as a slip ring or commutator.

[0055] As further shown in Figure 1, the brush holder assembly 12 has a conductive wire assembly 36 extending from the first end face 24 of the brush 14 to one or more different parts of the brush holder assembly 12 to transmit electricity from the brush 14 to the terminal 42. For example, the conductive wire assembly 36 extends from the first end face 24 of the brush 14 and is attached to the terminal 42, which is attached to a mounting block (not shown), part of the lower beam 32, part of the upper beam 30, or part of both the lower beam 32 and the upper beam 30. Although not shown for simplification, in some examples the lower beam 32 is removably engaged to another structure, such as a mounting block (not shown).

[0056] As described above, the brush holder assembly 12 is configured to maintain the state in which the conductive surface 26 of the brush 14 is in contact with the conductive surface 18 of the rotating part 20. When an electric current is generated by an electrical device (e.g., a collector ring, slip ring, or commutator), the current flows to the brush 14 through the movable (rotating, sliding, etc.) part 20. This transmits the current to the terminal 42 via the conductive lead assembly 36. Furthermore, since the terminal 42 is engaged with a mounting block (not shown), it can conduct current 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, terminals 42, and brushes 14, all of which are positioned separately (for clarity) from the rest of the brush holder assembly 12. The dashed lines in Figure 2 indicate the alignment of each component (e.g., terminals 42, conductive lead assembly 36, and brushes 14) with the lower beam 32 of the brush holder assembly 12. For simplification, the wear condition monitor 38, spacer 40, and spring 41 are omitted in Figure 2.

[0058] As shown in Figure 2, the conductive electrical lead assembly 36 has a first electrical lead wire 46. As will be described in detail later, 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., a splice connection, a welded connection) along the conductive lead assembly 36. Referring again to Figure 1, in the fully assembled state, 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 detail later, a portion of the second electrical lead wire 44a and the third electrical lead wire 44b is embedded in the brush 14). Furthermore, as shown in Figure 1, in the fully assembled state, the first electrical lead wire 46 is attached (e.g., welded) to a terminal 42, which is detachably attached to the lower beam 32 (as will be described in detail later).

[0059] Figure 3 shows the brush assembly 45 of the brush holder assembly 12 (shown in Figure 2), which has 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 the first electrical lead wire 46 of the conductive electrical lead assembly 36 to the terminal 42 in a separate manufacturing process, attach the second electrical lead wire 44a and / or the third electrical lead wire 44b to the brush 14 in another separate manufacturing process, and then splice (e.g., join, attach, connect, 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 Figure 3. The coupling structure of the terminal 42, conductive electrical lead assembly 36 and brush 14 shown in Figure 3 is then connected to the remaining parts of the brush holder assembly 12 to form the system 10 shown in Figure 1. If the brush 14 becomes worn during use, the worn brush assembly 45 (including the terminals 42, conductive electrical lead assembly 36, and worn brush 14) can be removed from the brush holder of the brush holder assembly 12 and replaced with another new brush assembly 45 containing a new, unused brush 14 and its associated terminals 42 and conductive electrical lead assembly 36.

[0060] Figure 4 is an exploded view of some of the components of the brush assembly 45 shown in Figure 3. For the sake of simplicity, the brush 14 is omitted in Figure 4. In Figure 4, the terminal 42 is shown spaced apart from the conductive electrical lead assembly 36. Furthermore, as shown in Figure 4, the conductive electrical lead assembly 36 also has a band 48 (shown spaced apart from the conductive electrical lead assembly 36). The band 48 is shown to be attached to the first electrical lead wire 46 above the joint 50, but the band 48 may be attached to the second electrical lead wire 44a and / or the third electrical lead wire 44b below the joint 50. This does not change the performance or function of the system 10 or its individual components. In some examples, the band 48 is a clip, strap or other structure configured to surround the end region of the first electrical lead wire 46 near the joint 50 (in another embodiment, 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 has 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 be removably connected to a part of the lower beam 32 and / or mounting block by engagement, meshing, etc., thereby fixing the terminal 42 to the lower beam 32 and / or mounting block and allowing current to flow between them.

[0062] As further shown in Figure 4, the terminal 42 has a first engaging arm 56a and a second engaging arm 56b. Together with the first side wall 55a and the second side wall 55b, the first engaging arm 56a and the second engaging arm 56b are designed to slide-engage with a portion of the lower beam 32. For example, the first engaging arm 56a and the second engaging arm 56b each have tip regions 58a / 58b, respectively, which are designed to engage with a portion of the lower beam 32. For example, the first engaging arm 56a and the second engaging arm 56b are designed to slide (e.g., hook, lock, etc.) on a portion of the lower beam 32, with the first and second engaging arms 56a / 56b positioned on the first side of the rear wall of the lower beam 32 and the first and second side walls 55a / 55b, and the lower surface 59 positioned on the second side opposite the rear wall of the lower beam 32. As shown in Figure 4, the terminal 42 defines a gap between the lower surface 59 and the tip regions 58a / 58b of the first engaging arm 56a and the second engaging arm 56b, and a portion of the lower beam 32 can slide within this gap. In other words, connecting the terminal 42 to the lower beam 32 involves sliding a portion of the rear wall of the lower beam 32 between both the tip regions 58a / 58b of the first engaging arm 56a and the second engaging arm 56b and the lower surface 59.

[0063] As further shown in Figure 4, the lower surface 59 has tabs 60 (e.g., projections, protrusions, bumps, etc.) that extend or project away from the surface of the lower surface 59. The tabs 60 engage with a mating opening (not shown in Figure 4) located in part of the lower beam 32. The tabs 60 are used to properly align and hold the terminal with the lower beam 32 and / or mounting block (not shown) when engaging and disengaging the brush holder assembly 12 with the electrical device. Furthermore, the engagement of the tabs 60 with the opening located in the lower beam 32 forms a meshing connection between the terminal 42 and the lower beam 42, to which the terminal 42 can be removably connected. The engagement of the terminal 42 with the lower beam 32 by the meshing of the tabs 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 unintentionally detaching from the lower beam 32 when the system 10 is mounted to the electrical device.

[0064] Furthermore, as shown in Figure 4, the terminal 42 has a mounting surface 54. The mounting surface 54 is located on the same plane as the lower surface 59 (for example, the mounting surface 54 and the lower surface 59 are a continuous, flat sheet material). The mounting surface 54 of the terminal 42 can be defined as the portion of the terminal 42 that is fixed to a part of the first electrical lead wire 46 by welding or the like.

[0065] As further shown in Figure 4, a mounting area 52 is provided on a portion of the first electric lead wire 46. The mounting area 52 is designed to be fixed to the mounting surface 54 of the terminal 42 by welding or the like (Figure 3 shows the mounting area 52 of the first electric lead wire 46 welded to the mounting surface 54 of the terminal 42 shown in Figure 4). In Figure 4, the mounting area 52 located along a portion of the first electric lead wire 46 is shown as a substantially flat surface. However, as will be shown in more detail below, the shape of the mounting area 52 of the first electric lead wire 46 may be the shape that results from the mounting area 52 being welded to the mounting surface 54 of the terminal 42. In other words, before being welded to the mounting surface 54, the first electric lead wire 46 may be substantially cylindrical along the mounting area 52.

[0066] Furthermore, as can be seen from both Figures 3 and 4, the terminal 42 has a first opening 57a and a second opening 57b. These are located on either side of the terminal 42, in close proximity to the terminal 42, between the mounting surface 54 of the terminal 42 and the first and second engaging arms 56a / 56b. The openings 57a / 57b are defined by the specific geometric shapes of the first engaging arms 56a and the second engaging arms 56b. For example, the first engaging arms 56a and the second engaging arms 56b have shapes (e.g., curved or bent shapes) that define the first opening 57a and the second opening 57b (together with the mounting surface 54). Furthermore, as shown in Figure 3 and further described below with reference to Figure 8, the first opening 57a and the second opening 57b are designed so that a portion of the first electrical lead wire 46 can pass through and extend.

[0067] As previously mentioned, the conductive wire assembly 36 shown in Figure 4 has a band 48. The band 48 is positioned on a portion of the first electrical lead wire 46. The band 48 may also be positioned 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 the first end 47 and the second end 49 of the first electrical lead wire 46 and securely fasten them over the splice 50 (i.e., between the splice 50 and the terminal 42). However, in some examples, the clip 48 may be detachably attached 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 further detailed below with reference to Figures 14 and 15), constructing the conductive electrical lead assembly 36 involves splicing (e.g., ultrasonic welding) the ends of the first electrical lead wire 46 with the ends of the second electrical lead wire 44a and / or the third electrical lead wire 44b. Specifically, Figure 4 shows a splice (e.g., welding) region 50 of the first electrical lead wire 46 with respect 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., welded joint, welded connection) obtained by splicing together (e.g., ultrasonic welding) 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 some examples, the splice region 50 consists of the first end region 47 of the first electric lead wire 46, the second end region 49 of the first electric lead wire 46, the first end region 62a of the second electric lead wire 44a, and the first end region 62b of the third electric lead wire 44b. In other examples, the splice region 50 has one or more end regions (one or both end regions, etc.) of the second electric lead wire 44a and / or the third electric lead wire 44b spliced ​​to one or more end regions (one or both end regions, etc.) of the first electric lead wire 46. In other examples, the splice region 50 has only one end region of the first electric lead wire 46 joined to one end region of either the second electric lead wire 44a or the third electric lead wire 44b.

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

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

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

[0072] The shape of the first electrical lead wire 46 shown in Figure 6 is substantially similar to the shape of the first electrical lead wire 46 shown in Figures 1-4 (for example, the shape of the electrical lead wire 46 in the fully assembled system 10 in Figure 1). Figure 6 also shows the first electrical lead wire 46 before it is welded to the terminal 42 (the welding of the second electrical wire 46 to the terminal 42 will be described later with reference to Figures 8 and 9). The terminal 42 is welded to the first electrical lead wire 46 either before or after the lead wire is formed into the shape shown in Figure 6.

[0073] As shown in Figure 6, the process of manufacturing the first electrical lead wire 46 from the raw material shown in Figure 5 into the molded configuration of the first electrical lead wire 46 includes the step of positioning the first end region 47 of the wire 46 adjacent to the second end region 49 of the wire 46. Furthermore, as shown in Figure 6, the molded configuration of the wire 46 has a curved portion 53 (part of which includes the mounting region 52 described above with reference to Figure 4).

[0074] Figure 7 shows the terminal 42 in its pre-formation configuration (for example, the configuration of the terminal 42 before it is formed and welded to the first electrical lead wire 46). As shown in Figure 7, before being formed into the final assembly configuration (for example, the configuration shown in Figures 1-4) (for example, by bending, forming, punching, machining, etc.), the terminal 42 resembles a flat sheet. The pre-formation terminal 42 shown in Figure 7 is machined (for example, cut) from a sheet-like raw material. In other words, the pre-formation terminal 42 shown in Figures 1-4 is first machined (for example, cut) from a flat sheet-like material into the shape shown in Figure 7. After being cut into the geometric shape shown in Figure 7, it is further formed into the shape of the terminal 42 shown in Figures 1-4 by bending, forming, punching, machining, etc.

[0075] The terminal 42 in its pre-molding configuration shown in Figure 7 has a lower surface 59, a portion of which is formed into a tab 60 (as described above with reference to Figure 4). The pre-molding configuration of the terminal 42 also has a first side wall 55a and a second side wall 55b positioned adjacent to the lower surface 59 and extending away from the lower surface 59. As shown in Figure 7, the pre-molding configuration of the terminal 42 has a mounting surface 54, and the portion of the terminal 42 that will be welded to the mounting area 52 (shown in Figure 4) of the first electrical lead wire 46 is defined by the mounting surface 54.

[0076] As shown in Figure 7, the pre-molding configuration of the terminal further includes a first engaging arm 56a and a second engaging arm 56b, both of which are positioned on either side of the upper surface 80 and extend away from the upper surface 80. As shown in Figure 7, the first engaging arm 56a and the second engaging arm 56b each have tip regions 58a / 58b.

[0077] As previously stated (and as will be described in more detail below), an exemplary manufacturing process of system 10 includes welding (e.g., ultrasonic welding) a first electrical lead wire 46 to a terminal 42, for example, to a mounting surface 54 of the terminal. As previously stated, in some examples, the first electrical lead wire 46 is formed from copper. In order to weld the copper wire to the terminal 42, at least a portion of the terminal 42 must be copper-weldable. In other words, in conventional welding techniques, the materials to be joined must be materials on which the welding process can be performed. 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 used herein include non-ferrous copper and non-ferrous copper alloys.

[0078] As shown in the detailed view of Figure 7, in some examples the terminal 42 is formed from a copper-clad material. For example, the detailed view of Figure 7 shows a cross-section of the wall of the terminal 42. The cross-sectional view shown in the detailed view of Figure 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 surface of the inner core material 66, and the second copper layer 68b extending continuously across the entire second surface on the opposite side of the inner core material 66. The inner core material 66 is steel or other metallic material such as elastic steel. In one example, the inner core material 66 is 1065 steel with an ultimate tensile strength of approximately 630-690 MPa, a yield tensile strength of approximately 380-490 MPa, and an elastic modulus of approximately 190-210 GPa. In some examples, the material composition of the terminal 42 shown in the detailed view of Figure 7 is referred to as "copper-plated" or "copper-coated" material. Furthermore, when the terminal 42 is formed from a multilayer material (e.g., plating material, coating material, copper-coated steel), an exposed end of the terminal 42 is obtained in which each layer of the material forming the multilayer material is visible. In the above example, at the exposed end of the copper-coated steel sheet, the ends of the first copper layer 68a, the second copper layer 68b, and the inner core material 66 (e.g., steel) are visible.

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

[0080] In some examples, after the terminal 42 is formed into an assembled configuration (Figures 1-4), the entire outer surface area of ​​the terminal 42 is plated with nickel. In some examples, the nickel used for plating the terminal 42 is low-phosphorus nickel. Low-phosphorus nickel inhibits corrosion. Furthermore, by plating the entire outer surface of the terminal 42 with low-phosphorus nickel material, the first electrical lead wire 46 can be easily ultrasonically welded to the terminal 42. In some examples, the thickness of the nickel plating is approximately 0.25-30 microns, approximately 0.50-15 microns, approximately 0.75-10 microns, approximately 1-5 microns, or less than 5 microns.

[0081] Furthermore, as can be seen from Figure 7 and the above description, since the first copper layer 68a is separated from the second copper layer 68b, the current that reaches the second copper layer 68b (via the conductive electrical lead assembly 36, etc.) through the nickel plating will reach the first copper layer 68a through the inner core layer 66. Thus, the current reaches the nickel plating layer from the surface 18 of the rotating part 20 of the electrical device, through the brush 14, the second electrical lead wire 44a and / or the third electrical lead wire 44b, the first electrical lead wire 46, the nickel plating layer, the second copper layer 68b, the inner core layer 66, and the first copper layer 68a. As a result, the current reaches the mounting block and can 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 mentioned above, the inner core material 66 has a first surface and a second surface on the opposite side, which are covered with a different material from the inner core material 66. In the examples above, the inner core material 66 is described as being covered with a copper material (i.e., copper and / or copper alloy), but various materials (e.g., metals, metal alloys, etc.) can be used to cover each surface of the inner core material 66. Examples of materials that can be used to cover each surface of the inner core material 66 include silver, aluminum, cadmium alloy, 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 (excluding the nickel plating layer of the material), the first copper layer 68a accounts for 10% of the total thickness, the second copper layer 68b accounts for 10% of the total thickness, and the inner core material 66 accounts for 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 approximately 5%, the thickness of the second copper layer 68b may be approximately 5%, and the thickness of the inner core material 66 may be approximately 90%. In other examples, the thickness of the first copper layer 68a may be approximately 15%, the thickness of the second copper layer 68b may be approximately 15%, and the thickness of the inner core material 66 may be approximately 70%. In other examples, the thickness of the first copper layer 68a is approximately 5% to 15%, the thickness of the second copper layer 68b is approximately 5% to 15%, and the thickness of the inner core material 66 is approximately 70% to 90%.

[0084] Figure 8 shows another example of the manufacturing process in the process of attaching (e.g., welding) the first electrical lead wire 46 to the terminal 42. As shown in Figure 8, before welding the first electrical lead wire 46 to the terminal 42, the first electrical lead wire 46 is positioned through openings 57a and 57b of the terminal 42 so that the mounting area 52 of the first electrical lead wire 46 is aligned (e.g., juxtaposed) with the mounting surface 54 of the terminal 42. As previously mentioned, the openings 57a / 57b of the terminal 42 are defined by the first engaging arm 56a and the second engaging arm 56b, respectively.

[0085] Furthermore, as shown in Figure 8, before welding the first electrical lead wire 46 to the terminal 42, the first electrical lead wire 46 extends longitudinally along the mounting surface 54 of the terminal 42, with the first end region 47 extending from the first side of the terminal 42 and the second end region 49 extending from the second side on the opposite side of the terminal 42. Thus, the mounting region 52 of the first electrical lead wire 46, which is the intermediate region of the first electrical lead wire 46, is aligned with the terminal 42 such that the end regions on both sides extend from the terminal 42 in both directions. The length of each end region of the first electrical lead wire 46 extending from the terminal 42 is, for example, 2.54 cm (1 inch) or more, 5.08 cm (2 inches) or more, or 7.62 cm (3 inches) or more. To achieve the pre-welding installation configuration shown in Figure 8, the raw material wire 46 shown in Figure 5 is inserted into each opening 57a / 57b of the terminal 42 until the mounting area 52 of the first electric lead wire 46 is properly aligned with the mounting surface 54 of the terminal 42. Thus, the terminal 42 is located approximately in the center between the first end area 47 and the second end area 49 of the first electric lead wire 46, with the first electric lead wire 46 extending from both sides of the terminal 42 by approximately equal lengths.

[0086] Figure 9 shows another example of the manufacturing process in the process of attaching (e.g., welding) the first electrical lead wire 46 to the terminal 42. Specifically, Figure 9 shows the first electrical lead wire 46 after the mounting area 52 of the lead wire 46 has been fixed to the mounting surface 54 of the terminal 42 by welding or the like, and the first electrical lead wire 46 has been formed into a curved configuration (having a shape similar to the shape of the first electrical lead wire after it has been fully assembled, as shown in Figures 1-4).

[0087] As mentioned above, Figure 9 shows that after the first electrical lead wire 46 is welded and bent, the end regions 47 / 49 on both sides of the first electrical lead wire 46 extend from the terminal 42, and the first electrical lead wire 46 is positioned by passing through the openings 57a and 57b of the terminal 42. In other words, after the electrical lead wire 46 is welded and bent into the configuration shown in Figure 9, each portion of the first electrical lead wire 46 extending away from the mounting surface 54 is passed through the openings 57a / 57b, respectively, and then the first end region 47 is aligned with the second end region 49 in a curved shape.

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

[0089] Figure 10 shows an exemplary configuration of the second and third electrical lead wires 44a and / or third electrical lead wires 44b before they are formed and attached to the brush 14, in their unformed (e.g., raw material) state. As shown in Figure 10, the unformed configurations of the second electrical lead wire 44a and third electrical lead wire 44b are substantially similar to cylindrical wires having a first end 62a / 62b (as previously described with reference to Figure 4) and a second end 64a / 64b (as previously described with reference to Figure 4) opposite the first end 62a / 62b. In some examples, the second and third electrical lead wires 44a / 44b are made of copper. However, in other examples, the second and third lead wires 44a / 44b may be formed from a variety of different conductive materials. For example, the second and third electrical lead wires 44a / 44b may be made of aluminum, silver, etc.

[0090] As further shown in Figure 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 Figure 10 each contain 11 individual wires 61 wound together to form the electrical lead wires 44a / 44b. However, in the second and third electrical lead wires 44a / 44b, the number of individual wires 61 wound together to form the electrical lead wires 44a / 44b may be more or less than 11. 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 (for example, the electrical lead wires 44a / 44b may be formed from a single solid cylindrical wire).

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

[0092] The shapes of the second electrical lead wire 44a and the third electrical lead wire 44b shown in Figure 11 are substantially similar to the shapes of the second electrical lead wire 44a and the third electrical lead wire 44b shown in Figures 1-4 (for example, the shapes of the second electrical lead wire 44a and the third electrical lead wire 44b of the fully assembled system 10 in Figure 1). Also shown in Figure 11 are the second electrical lead wire 44a and the third electrical lead wire 44b before they are attached to the brush 14.

[0093] As shown in Figure 11, forming the two separate unprocessed electrical lead wires 44a / 44b shown in Figure 10 into the molded configurations of a second electrical lead wire 44a and a third electrical lead wire 44b involves 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] Figure 12 shows an example of a manufacturing process in which portions of the second electrical lead wire 44a and the third electrical lead wire 44b are fixed to the brush 14. Attaching the second electrical lead wire 44a and the third electrical lead wire 44b to the brush 14 involves positioning the second electrical lead wire 44a and the third electrical lead wire 44b within corresponding holes (e.g., pre-formed holes, bores and / or openings) in the brush 14. After the respective second end regions 64a / 64b of the second wire 44a and the third wire 44b are positioned within the respective holes of the brush 14, each hole is filled (e.g., packed) with additional powder material (e.g., carbon powder material), thereby fixing the second end regions 64a / 64b of both the second electrical lead wire 44a and the third electrical lead wire 44b to the brush 14. The second end regions 64a / 64b of the second electrical lead wire 44a and the third electrical lead wire 44b, which are embedded within the brush 14, are shown by dashed lines in Figure 12. In other words, Figure 12 shows that the brush 14 includes two or more individual electrical lead wires extending from the brush 14, and that each end region of the individual lead wires is fixed to the brush 14 by being embedded in the brush 14, etc. The free end on the opposite side of each lead wire extends from the brush 14 and is fixed to another electrical lead wire in the splice region 50. In other examples, only one electrical lead wire (such as the second electrical lead wire 44a) is fixed to the brush 14 (for example, having an end region embedded in a hole in the brush 14), and extends from the brush 14 and is fixed to another electrical lead wire (an electrical lead wire extending from terminal 42) in the splice region 50.

[0095] Furthermore, as shown in Figure 12, after the second electrical lead wire 44a and / or the third electrical lead wire 44b are attached to the brush 14, the first end region 62a of the second electrical lead wire 44a is positioned adjacent to the first end region 62b of the third electrical lead wire 44b. In addition, as shown in Figure 12, the ends of the second electrical lead wire 44a and the third electrical lead wire 44b are spaced apart from each other at the points where the respective parts of the second electrical lead wire 44a and the third electrical lead wire 44b extend from the brush 14. The outer widthwise distance between the spaced-away ends of the second electrical lead wire 44a and the third electrical lead wire 44b is shown as dimension Y in Figure 12. However, as further shown in Figure 12, the ends 62a / 62b of the second and third electric lead wires 44a and 44b are curved to converge toward the centerline of the brush 14, and the first end regions 62a / 62b of the second and third electric lead wires 44a and 44b are adjacent to each other. The outer widthwise distance between the end regions 62a / 62b of the second and third electric lead wires 44a and 44b at the point where the first end regions 62a / 62b are adjacent to each other is shown as dimension X in Figure 12. In some examples, dimension Y is greater than dimension X.

[0096] Figures 13-15 and the accompanying descriptions illustrate exemplary manufacturing steps for welding (e.g., ultrasonic welding) the second electric lead wire 44a and the third electric lead wire 44b to the first electric lead wire 46.

[0097] Figure 13 shows an exemplary welding fixture 72. As shown in Figure 14, the exemplary fixture 72 is configured to hold the first ends of the second electric lead wire 44a and the third electric lead wire 44b together with the first and second ends of the first electric lead wire 46 while they are being welded. Furthermore, the fixture 72 is designed to align the first ends of the second electric lead wire 44a and the third electric lead wire 44b together with the first and second ends of the first electric lead wire 46 while they are being welded.

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

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

[0100] Furthermore, in the fixture 72 shown in Figure 13, the alignment grooves 74a / 74b (or a single alignment groove for the first end regions 62a / 62b of the second and third electric lead wires 44a / 44b) are 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 electric lead wire 46), and a welding area 75 is formed within the cavity of the fixture 72. The alignment of the first ends of the second electric lead wire 44a and the third electric lead wire 44b and the end of the first electric lead wire 46 within the welding area 75 before welding will be described later with reference to Figure 14.

[0101] Furthermore, the fixture 72 includes one or more clamping members 82a / 82b for aligning the ends of the first electric lead wire 46, the second lead wire 44a, and the third lead wire 44b by tightening or other means during the welding process. For example, the fixture 72 has a first clamping member 82a on the first side of the welding area 75 and a second clamping member 82b on the second side of the welding area 75. The first and second clamping members 82a / 82b are movable toward each other within the fixture 72 in order to align the ends of the first electric lead wire 46, the second lead wire 44a, and the third lead wire 44b between them by tightening or compressing or other means.

[0102] Figure 14 shows the first end 62a of the second electric lead wire 44a, the first end 62b of the third electric lead wire 44b, and the first and second ends 47 / 49 of the first electric lead wire 46, positioned within the welding area 75 before welding by the welding apparatus 76. Specifically, Figure 14 shows the first end region 62a of the second electric lead wire 44a positioned within the alignment groove 74a of the fixture 72, the first end region 62b of the third electric lead wire 44b positioned within the alignment groove 74b of the fixture 72, the first end region 47 of the first electric lead wire 46 positioned within the alignment groove 73a of the fixture 72, and the second end region 49 of the first electric lead wire 46 positioned within the alignment groove 7b of the fixture 72.

[0103] As mentioned above, in other examples, both the first end region 47 and the second end region 49 of the first electric lead wire 46 are positioned adjacent to each other within the welding area 75 via a single alignment groove. Furthermore, both the first end region 62a of the second electric lead wire 44a and the first end region 62b of the third electric lead wire 44b are positioned adjacent to each other within the welding area 75 via a single alignment groove.

[0104] As further shown in Figure 14, the first end region 62a of the second electric lead wire 44a and the first end region 62b of the third electric lead wire 44b (already fixed to the brush 14) are positioned to overlap (i.e., vertically above and overlapping) the first end region 47 and the second end region 49 of the first electric lead wire 46 (already fixed to the terminal 42). In other words, the first end region 47 and the second end region 49 of the first electric lead wire 46 are located below the first end region 62a of the second electric lead wire 44a and the first end region 62b of the third electric lead wire 44b. Referring again to Figure 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 electric lead wires 44a / 44b) is higher than the first pair of alignment grooves 73a / 73b (or a single alignment groove for receiving the end region 47 / 49 of the first electric lead wire 46) so that the end region 47 / 49 of the first electric lead wire 46 is positioned below the end regions 62a / 62b of the second and third electric lead wires 44a / 44b. In another embodiment, the fixture 72 is designed so that the end region 47 / 49 of the first electric lead wire 46 is positioned above the end regions 62a / 62b of the second and third electric lead wires.

[0105] Furthermore, as shown in Figure 14, in some examples, before welding, the first end region 62a of the second electric lead wire 44a and the first end region 62b of the third electric lead wire 44b overlap (for example, extend beyond the overlap) with a portion of the first end region 47 and the second end region 49 of the first electric lead wire 46 within the welding area 75. In other words, before welding, the first end region 62a of the second electric lead wire 44a, the first end region 62b of the third electric lead wire 44b, the first end region 47 of the first electric lead wire 46, and the second end region 49 of the first electric lead wire 46 are positioned within the welding area 75 such that the first end region 62a of the second electric lead wire 44a and the first end region 62b of the third electric lead wire 44b extend adjacently along the first end region 47 and the second end region 49 of the first electric lead wire 46.

[0106] As further shown in Figure 14, the first electric lead wire 46 is attached to the terminal 42 (e.g., welded) and the second electric lead wire 44a and the third electric lead wire 44b are attached to the brush 14 (e.g., embedded). The fixture 42 is designed to allow the first electric lead wire 46 to be welded to the second electric lead wire 44a and / or the third electric lead wire 44b after the first electric lead wire 46 is attached to the terminal 42 and the second electric lead wire 44a and / or the third electric lead wire 44b are attached to the brush 14.

[0107] After the end regions 62a / 62b of the second and third electric lead wires 44a / 44b and the end region 47 / 49 of the first electric lead wire 46 are aligned within the cavity of the fixture 72, the clamping members 82a / 82b are operated to align the end regions 62a / 62b and the end region 47 / 49 with each other by clamping or compressing. Furthermore, the welding device 76, such as an ultrasonic welding machine, is advanced toward the welding area 75 to press the end regions 62a / 62b of the second and third electric lead wires 44a / 44b (or, if the end region 47 / 49 of the first electric lead wire 46 is positioned above the end regions 62a / 62b of the second and third electric lead wires 44a / 44b, then the end region 47 / 49 of the first electric lead wire 46) and close the upper part of the cavity of the fixture 72 that defines the welding area 75. While being compressed together, the end regions 62a / 62b and 47 / 49 are welded together by a welding device 76 (e.g., an ultrasonic welding machine). For example, the welding device 76 vibrates at a high frequency to move back and forth in a direction parallel to the axis of the end regions of the electric lead wires 44a / 44b / 46 in the fixture 72, thereby ultrasonically welding the end regions together.

[0108] Figure 15 shows the first end region 62a of the second electric lead wire 44a, the first end region 62b of the third electric lead wire 44b, the first end region 47 of the first electric lead wire 46, and the second end region 49 of the first electric lead wire 46, which are welded together by the welding apparatus 76 (see Figure 14) to form a welded (e.g., jointed) region 50. The welded region 50 may also be referred to as a welded joint or welded connection. As can be seen from the assembly shown in Figure 15, in the conductive lead assembly 36, the first electric lead wire 46 is directly attached to the terminal 42, and the second electric lead wire 44a and the third electric lead wire 44b are directly attached to the brush 14. Therefore, although the second electric lead wire 44a and the third electric lead wire 44b are directly attached to the brush 14, they do not extend to the terminal 42. Similarly, the first electrical lead wire 46 is directly attached to the terminal 42 but does not extend to the brush 14. In other words, the second electrical lead wire 44a and / or the third electrical lead wire 44b extend only between the welded joint 50 and the brush 14, and the first electrical lead wire 46 extends only between the welded joint 50 and the terminal 42. The assembly shown in Figure 15 is integrated with the remaining parts of the brush holder assembly 12 (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, where 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 are terminated at a welded joint region 50.

[0110] Furthermore (referring again to the description in Figure 12), as shown in Figure 16A, the two ends of the second electrical lead wire 44a and the third electrical lead wire 44b are spaced apart from each other where their respective end regions exit the brush 14. As previously mentioned with reference to Figure 12, the outer width between the spaced ends of the second electrical lead wire 44a and the third electrical lead wire 44b is shown as dimension Y in Figure 16A (this is the same as dimension Y shown in Figure 12).

[0111] Furthermore, as can be seen from Figure 16A, the outer dimensions in the width direction of the outer edge of the first end region 47 of the first electric lead wire 46, the second end region 49 of the first electric lead wire 46, the first end region 62a of the second electric lead wire 44a, the first end region 62b of the third electric lead wire 44b, and the welding region 50 are all smaller than dimension Y. The width of the welding 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, which terminate in the welding area 50) is smaller than the width Y, so that when the brush 14 moves in parallel towards the surface 18 (Figure 1) of the rotating part 20 (Figure 1) of the electrical device within the internal 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), the parts of the first electrical lead wire 46, the second electrical lead wire 44a, and the third electrical lead wire 42b do not get caught on the brush holder 16 (Figure 1) or the edge of the brush holder 16.

[0112] Furthermore, as shown in Figure 16B, the first end regions 62a / 62b of the second and third electric lead wires 44a / 44b are positioned closer to the front surface of the brush 14 than the end region 47 / 49 of the first electric lead wire 46. As a result, as the brush 14 wears down and its length decreases, the welded joint 50 moves inward into the brush holder 16, preventing the end portion of the first electric lead wire 46 (facing or directed toward the brush 14) from catching on the upper edge of the brush holder 16. Therefore, the end region 47 / 49 of the first electric lead wire 46 is positioned closer to the longitudinal central axis of the brush 14 than the first end regions 62a / 62b of the second and third electric lead wires 44a / 44b, and the first end regions 62a / 62b of the second and third electric lead wires 44a / 44b are closer to the front edge of the brush 14. In other words, the end regions of the wires 44a / 44b / 46 are positioned such that the movement of the welded joint 50 into the brush holder 16 is not obstructed by the 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 brush holder 16.

[0113] Furthermore, referring again to Figure 15, the end regions of wires 44a / 44b are positioned as described above with respect to the end of the first lead wire 46 before welding (as shown in Figure 14, the end regions of wires 44a / 44b are positioned closer to the leading edge of the brush than to the end of the first lead wire 46), thereby forming a welded joint 50 having a downward-facing shelf-like portion (e.g., lip, edge, face, etc.) facing the upper surface of the brush 14. However, since the shelf-like portion 63 is located inward toward the centerline of the brush 14, it is prevented from catching on the upper edge of the brush holder 16 as the brush 14 moves into the brush holder 16 as it wears down and shortens. The downward-facing shelf-like portion 63 of the welded joint 50 is formed by the end of the first lead wire 46. As shown in Figure 15, the ends of the second and third electric lead wires 44a / 44b also form shelf-like portions 65 (e.g., lip portions, edges, surfaces, etc.) of the welded joint 50 that face upward away from the brush 14. The upward orientation of the shelf-like portions 65 does not hinder the movement of the welded joint that enters the inside of the brush holder 16.

[0114] Figure 17 shows an exemplary brush holder assembly 12 described herein, positioned along the conductive surface 18 of a rotating part 20 of an electrical device. Figure 17 shows a brush 14 (as described above with respect to Figure 1) positioned within the brush holder 16, with the lower surface 26 of the brush 14 engaging with the conductive surface 18 of the rotating part 20. As the lower surface 26 remains in contact with the conductive surface 18 of the rotating part 20, the upper surface 24 of the brush 14 moves linearly parallel to the conductive surface 18 within the brush holder 16 due to wear of the lower surface 26.

[0115] In some cases, it is desirable to monitor the distance the upper surface 24 moves parallel to within the brush holder 16 to determine the degree of wear of the brush 14. For example, it is desirable to monitor the distance the upper surface 24 of the brush 14 moves relative to the upper edge 78 of the brush holder 16 or to other reference points located at a certain distance from the conductive surface 18. The distance the upper surface 24 moves relative to the upper edge 78 of the brush holder 16 (or other fixed reference point) represents the amount of brush material removed from the lower surface 26 of the brush 14 (i.e., how much the brush 14 has worn or shortened during use).

[0116] In some cases, it may be difficult to monitor the distance the upper surface 24 has moved relative to the upper edge 78 of the brush holder 16. Therefore, in some cases, the distance the upper surface 24 of the brush 14 has moved relative to the upper edge 78 of the brush holder 16 is determined by using another part of the brush holder assembly 12 located at a certain distance from the conductive surface 18 as a reference point.

[0117] As shown in Figure 17, in some examples, the distance the upper surface 24 of the brush 14 has moved relative to the upper edge 78 of the brush holder 16 is determined by using a 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)) as a reference point. For example, in Figure 17, the initial distance of the band 48 from the upper edge 78 at a first time point is shown as dimension Z. As the lower surface 26 of the brush 14 wears down, the distance Z decreases. By monitoring the change in distance Z, the amount of brush material removed from the lower surface 26 of the brush 14 can be determined, thereby determining the degree of wear and length reduction of the brush 14 during use. If the wear of the brush 14 exceeds a threshold amount, the brush 14 can be removed along with the terminals 42 and associated conductive electrical lead assembly 36 and replaced with a new brush assembly 45.

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

[0119] In some examples, the brush holder assembly 12 described herein functions similarly to the conductive wire assembly 36 but comprises an alternative conductive wire assembly having one or more different parts and / or manufacturing methods compared to the conductive wire assembly 36. For example, Figure 18 shows various parts of another exemplary conductive wire assembly 136 that engages with and extends from the brush 114. The shape and function of the brush 114 are similar to those of the brush 14 described herein.

[0120] Figure 18 shows an exemplary manufacturing process in which a first electric lead wire 146 and a second electric lead wire 144 are pre-fixed to a brush 114. As shown in Figure 18, the first electric lead wire 146 has a first end region 147, a second end region 149, and an intermediate region extending between the first end region 147 and the second end region 149. The second electric lead wire 144 has a first end region 164 and a second end region 165. Furthermore, as shown in Figure 18, the first electric lead wire 146 is longer than the second electric lead wire 144 before they are welded together (which is done in a subsequent manufacturing process). In other words, the first electric lead wire 146 has a first length extending from the upper surface of the carbon brush 114 to the free end of the first electric lead wire 146 in the first end region 147, and the second electric lead wire 144 has a second length extending from the upper surface of the carbon brush 114 to the free end of the second electric lead wire 144 in the first end region 164. The first length is longer than the second length.

[0121] The first electrical lead wire 146 (e.g., the second end region 149 of the first electrical lead wire 146) and / or the second electrical lead wire 144 (e.g., the second end region 165 of the second electrical lead wire 144) are fixed to the carbon brush 114 in a desired manner. Attaching the first electrical lead wire 146 and / or the second electrical lead wire 144 to the brush 114 involves positioning the first electrical lead wire 146 and the second electrical lead wire 144, respectively, within corresponding holes (e.g., pre-formed holes, bores and / or openings) in the brush 114. After the second end regions 149 of the first lead wire 146 and the second end region 165 of the second lead wire 144 are positioned in the respective holes of the brush 114, additional powder material (e.g., carbon powder material) is filled into each hole, thereby securing the second end regions 149 / 165 of both the first and second electrical lead wires 146 and 144 to the brush 114. As shown in Figure 12, the second end regions 149 / 165 of the first and second electrical lead wires 146 and 144 embedded in the brush 114 are shown as dashed lines in Figure 18. In other words, Figure 18 shows that the brush 114 includes two or more individual electrical lead wires extending from the brush 114, and that the respective end regions of the individual lead wires are secured to the brush 114 by being embedded in the brush 114, etc. As described below, the first ends 147 / 164, which are the opposite free ends of the first lead wire 146 and the second lead wire 144, extend from the brush 114 and are fixed to each other in the splice region 150 (Figure 21).

[0122] Similar to Figure 12, as shown in Figure 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 at the points where the respective parts of the first electrical lead wire 146 and the second electrical lead wire 144 extend from the brush 114.

[0123] Furthermore, as shown in Figure 18, before welding the first end region 147 of the first electric lead wire 146 to the first end region 164 of the second electric lead wire 144, the terminal 142 is attached (welded, etc.) to the intermediate region of the first electric lead wire 146 at a position between the first end region 147 and the second end region 149, with the first end region 147 of the first electric lead wire 146 extending from the first side of the terminal 142, and the second end region 149 of the first electric lead wire 146 extending from the second side opposite the terminal 142. The shape and function of the terminal 142 are similar to those of the terminal 42 described herein. Furthermore, as shown in Figure 18, in some examples, the terminal 142 is welded along the first electric lead wire 146 at a position closer to the first end region 147 than to the second end region 149 of the first electric lead wire 146 (embedded in the brush 114). In other words, terminal 142 is welded to the intermediate region of the first electric lead wire 146 such that the length of the first electric lead wire 146 extending between terminal 142 and the carbon brush 114 is longer than the length of the first electric lead wire 146 extending between terminal 142 and the free end (first end region 147) of the first electric lead wire 146.

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

[0125] After positioning terminal 142 at the desired location along lead wire 146, the first electrical lead wire 146 is fixed to terminal 142 by welding or the like. Attaching terminal 142 to the first lead wire 146 can be done by the same process as described above for attaching terminal 42 and lead wire 46 in Figures 8 and 9. Fixing terminal 142 to the first lead wire 146 by welding or the like can be done before or after attaching the first lead wire 146 and / or the second lead wire 144 to the brush 114.

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

[0127] Furthermore, as shown in Figure 19, portions of both the first electric lead wire 146 and the second electric lead wire 144 are adjacent to each other (for example, the free ends of the first and second electric lead wires 146 / 144). For example, as shown in Figure 19, the first electric lead wire 146 and the second electric lead wire 144 are curved to converge toward the centerline of the brush 114, and therefore, before they are welded together, the first electric lead wire 146 and the second electric lead wire 144 are positioned adjacent to each other.

[0128] Figures 20 and 21 show examples of manufacturing processes similar to those described with reference to Figures 14 and 15. For example, as shown in Figure 20, before welding is performed by the welding apparatus 76, the first end region 147 of the first electric lead wire 146 (including the free end of the first electric lead wire 146) and the first end region 164 of the second electric lead wire 144 (including the free end of the second electric lead wire 144) are positioned within the welding area. In some examples, the intermediate region of the first electric lead wire 146 is positioned juxtaposed with the first end region 147 of the first electric lead wire 144 and the first end region 164 of the second electric lead wire 146 within the welding area. For example, Figure 20 shows the first end region 147 of the first electric lead wire 146, the first end region 164 of the second electric lead wire 144, and the intermediate region of the first electric lead wire 146 held in their pre-welding positions by the fixture 172. The form and function of the fastener 172 are the same as those of the fastener 72 described herein.

[0129] As further shown in Figure 20, the first end region 164 of the second electric lead wire 144 (the second end region 165 of the second electric lead wire 144 is already fixed to the brush 114) is superimposed on the first end region 147 of the first electric lead wire 146 (the second end region 149 of the first electric lead wire 146 is already fixed to the brush 114) (i.e., they are positioned vertically above and overlapping). In this configuration, the first end region 164 of the second electric lead wire 144 is positioned above the first end region 147 of the first electric lead wire 146. In other words, the first end region 147 of the first electric lead wire 146 is positioned below the first end region 164 of the second electric lead wire 144. Similar to the above description of the fastener 72, the fastener 172 is designed to position the first end region 147 of the first electric lead wire 146 below the second end region 164 of the second electric lead wire 144 before the lead wires are welded together. Thus, as shown in Figure 20, in some examples, before welding, the first end region 147 of the first electric lead wire 146 overlaps with (for example, extends beyond) a portion of the first end region 164 of the second electric lead wire within the welding area of ​​the welding apparatus 76.

[0130] Furthermore, as shown in Figure 20, the first end region 147 of the first electric lead wire 146 is welded to the first end region 164 of the second electric lead wire 144, and optionally the intermediate region of the first electric lead wire 146 is welded to the first end regions 147 / 164 of the first and second electric lead wires 146 / 144, before the first electric lead wire 146 is attached to (e.g., welded to) the terminal 142 (above), and the first electric lead wire 146 and the second electric lead wire 144 are attached to (e.g., embedded in) the brush 114. The fastener 172 is designed so that, after the first electric lead wire 146 is attached to the terminal 142 and the first electric lead wire 146 and / or the second electric lead wire 144 are attached to the brush 114, the first end region 147 of the first electric lead wire 146, the first end region 164 of the second electric lead wire 144 and / or the intermediate region of the first electric lead wire 146 can be welded together.

[0131] After the first end region 147 of the first electric lead wire 146, the first end region 164 of the second electric lead wire 144, and / or the intermediate region of the first electric lead wire 146 are aligned within the fixture 172, a welding device 76, such as an ultrasonic welding machine, advances toward the first end region 147 of the first electric lead wire 146, the first end region 164 of the second electric lead wire 144, and / or the intermediate region of the first electric lead wire 146, and ultrasonically welds the end regions 147 / 164 together to form a joint. During the welding process, the first end region 147 of the first electric lead wire 146 is welded to the first end region 164 of the second electric lead wire 144. Furthermore, in some examples, a portion of the intermediate region of the first electric lead wire 146, juxtaposed with the first end regions 147 / 164 of the first and second electric lead wires 146 / 144, is welded to the first end region 147 of the first electric lead wire 146 and / or the first end region 164 of the second electric lead wire 144. The process of welding the first end region 147 of the first electric lead wire 146, the first end region 164 of the second electric lead wire 144 and / or the intermediate region of the first electric lead wire 146 is similar to the welding process described with reference to Figures 14 and 15.

[0132] Figure 21 shows a state in which the first end region 147 of the first electric lead wire 146, the first end region 164 of the second electric lead wire 144, and the intermediate region of the first electric lead wire 146 are all welded together by a welding device 76 (shown in Figure 20) to form a splice joint 150 (e.g., splice joint, welded joint) along the conductive lead assembly 136. The splice joint 150 is also called a welded joint, welded region, welded joint, etc., and is obtained by splicing together (e.g., ultrasonic welding) the first end region 147 of the first electric lead wire 146, the first end region 164 of the second electric lead wire 144, and optionally a portion of the intermediate region of the first electric lead wire 146. In some examples, the weld or joint region 150 is formed solely by welding the first end region 147 of the first electric lead wire 146 to the first end region 164 of the second electric lead wire 144. In the lead assembly 136 shown in Figure 21, the first electric lead wire 146 is directly attached to the terminal 142, and a first portion 152 of the first electric lead wire 146 extends continuously from the terminal 142 to the brush 114 through the weld or joint or region 150, while a second portion 154 of the first electric lead wire 146 extends from the terminal 142 and terminates at the weld or joint or region 150. The second electric lead wire 144, which is directly attached to the brush 114, extends from the brush 114 and terminates at the weld or joint or region 150. Therefore, the first portion 152 of the first electric lead wire 146 is directly attached to the brush 114 and extends through the splice 150 to the terminal 142. On the other hand, the second portion 154 of the first electric lead wire 146 is directly attached to the terminal 142 but does not extend to the brush 114 (i.e., it terminates at the splice 150). Furthermore, the second electric lead wire 144 extends only between the welded splice 150 and the brush 114.

[0133] Furthermore, as shown in Figure 21, in some examples of the conductive lead assembly 136, wear marks 151 are provided on one or more surfaces of the welded joint 150. The wear marks 151 can be applied or formed on the welded joint 150 by methods such as etching, marking, or ink application. The wear marks 151 are positioned at a predetermined distance from the upper surface of the brush 114. For example, the wear marks 151 are positioned approximately 3.81 cm (approximately 1.5 inches) from the upper surface of the brush 114, with the conductive lead assembly 136 extending away from the upper surface of the brush 114. As will be described in detail below, the wear marks 151 can visually indicate the amount of wear or reduction of the brush 114 during use.

[0134] The conductive lead assembly 136 shown in Figure 21 is integrated with the remaining parts of the brush holder assembly 12 (for example, the brush holder 16, the lower beam 32, the upper beam 30, and the handle 22).

[0135] Figure 22 shows an exemplary conductive lead assembly 136 integrated with a brush holder assembly 12. The brush holder assembly 12 is positioned along the conductive surface 18 of a rotating part 20 of an electrical device. For example, Figure 22 shows a brush 114 (similar to the one described above with respect to Figure 1) positioned within a brush holder 16, with the lower surface 126 of the brush 114 engaging with the conductive surface 18 of the rotating part 20. If the lower surface 126 remains in contact with the conductive surface 18 of the rotating part 20, the lower surface 126 will wear down, causing the upper surface 124 of the brush 114 to move linearly parallel to the conductive surface 18 within the brush holder 16.

[0136] As described herein, it is desirable to monitor the distance the upper surface 124 of the brush 114 moves parallel to within the brush holder 16 to determine the degree of wear and reduction in length of the brush 114. For example, it is desirable to monitor the distance the upper surface 124 of the brush 114 moves relative to the upper edge 78 of the brush holder 16 or to other reference points located at a constant distance from the conductive surface 18. The distance the upper surface 124 moves relative to the upper edge 78 (or other constant reference point) of the brush holder 16 represents the amount of brush material removed from the lower surface 126 of the brush 114 (i.e., how much the brush 114 has worn or shortened during use).

[0137] As shown in Figure 22, in some examples, a wear mark 151 along the joint region 150 is used as a reference point for determining the distance the upper surface 124 of the brush 114 has moved relative to the upper edge 78 of the brush holder 16. For example, in Figure 22, the initial distance from the upper edge 78 to the wear mark 151 at a first point in time is shown as dimension A. As the lower surface 126 of the brush 114 wears down, distance A decreases. By monitoring the change in distance A, the amount of brush material removed from the lower surface 126 of the brush 114 can be determined, thereby determining the degree of wear and length reduction of the brush 114 during use. If the wear of the brush 114 exceeds a threshold amount, the brush 114 can be removed along with the terminals 142 and associated conductive electrical lead assembly 136 and replaced with a new brush assembly.

[0138] Those skilled in the art will recognize that aspects of this disclosure can be embodied in various forms other than the specific embodiments described and envisioned herein. Accordingly, modifications in form and detail are possible without departing from the scope and spirit of this disclosure as set forth in the appended claims.

Claims

1. A brush assembly, A single carbon brush having an upper surface and a lower surface, A first lead wire comprising a first end region and a second end region, and extending continuously from the first end region to the second end region of the first lead wire, A second lead wire comprising a first end region and a second end region, and extending continuously from the first end region to the second end region of the second lead wire, A third lead wire comprising a first end region and a second end region, and extending continuously from the first end region to the second end region of the third lead wire, A conductive terminal attached to the first lead wire, wherein the first end region and the second end region of the first lead wire extend in a direction away from the conductive terminal, The first end region of the first lead wire is joined to the first end region of the second lead wire by a single splice joint. The second end region of the first lead wire is joined to the first end region of the third lead wire at a single splicing joint. The second end region of the second lead wire and the second end region of the third lead wire are joined to a single carbon brush. The brush assembly wherein the joint portion is located between the conductive terminal and the carbon brush, and is provided at a position spaced apart from both the conductive terminal and the carbon brush.

2. In the brush assembly according to claim 1, The conductive terminal is fixed to the intermediate region of the first lead wire in a brush assembly.

3. In the brush assembly according to claim 2, The intermediate region of the first lead wire is ultrasonically welded to the conductive terminal, forming a brush assembly.

4. In the brush assembly according to claim 1, The aforementioned 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, respectively, in a brush assembly.

5. In the brush assembly according to claim 1, A brush assembly in which the second end region of the second lead wire is embedded in the upper surface of the carbon brush at a first position, and the second end region of the third lead wire is embedded in the upper surface of the carbon brush at a second position, with the first position spaced apart from the second position.

6. In the brush assembly according to claim 1, A brush assembly in which the aforementioned joint portion has wear marks, and these wear marks are used as reference points for determining the reduction in the carbon brush due to wear.

7. In the brush assembly according to claim 1, A brush assembly in which the conductive terminal has an inner core layer located between a first conductive metal layer and a second conductive metal layer.

8. In the brush assembly according to claim 7, A brush assembly in which the inner core layer contains steel.

9. In the brush assembly according to claim 8, A brush assembly in which the first conductive metal layer, the second conductive metal layer, or both the first conductive metal layer and the second conductive metal layer contain copper.

10. In the brush assembly according to claim 1, The first lead wire forms a loop portion extending from the joint portion of the brush assembly.

11. A brush assembly, A single carbon brush having an upper surface and a lower surface, A first lead wire comprising a first end region and a second end region, and extending continuously from the first end region to the second end region of the first lead wire, A second lead wire comprising a first end region and a second end region, extending continuously from the first end region to the second end region, the second end region of the second lead wire being fixed to a single carbon brush, A third lead wire comprising a first end region and a second end region, extending continuously from the first end region to the second end region, the second end region of the third lead wire being fixed to a single carbon brush, A conductive terminal attached to the intermediate region of the first lead wire, wherein the first end region and the second end region of the first lead wire extend in a direction away from the conductive terminal, A single joint portion is provided, which is located between the conductive terminal and the carbon brush and is spaced apart from both the conductive terminal and the carbon brush, A brush assembly in which a single splice joint is formed by making a loop shape out of the portion extending from the splice joint in the intermediate region of the first lead wire, and 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, respectively.

12. In the brush assembly according to claim 11, The intermediate region of the first lead wire is ultrasonically welded to the conductive terminal, forming a brush assembly.

13. In the brush assembly according to claim 11, A brush assembly in which the second end region of the second lead wire is embedded in the upper surface of the carbon brush at a first position, and the second end region of the third lead wire is embedded in the upper surface of the carbon brush at a second position, with the first position spaced apart from the second position.

14. In the brush assembly according to claim 11, A brush assembly in which the joint portion has wear marks, and the wear marks are used as reference points for determining the reduction due to wear of the carbon brushes.

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