Brush Assembly Guide Rail Elastic Fixation for High-Temp Motors
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Solution Overview
Problem
Existing brush assemblies for electric motors are not sufficiently rigidly fixed, leading to excessive movement and damage at high temperatures, and are not suitable for high-power, totally enclosed motors due to material limitations and design constraints.
Innovation Solution
A brush assembly with a W-shaped guide rail and resiliently deformed guiding arms that are locked into slots by protrusions, providing a secure and stable fixation without damaging the locking projections, using a combination of U-shaped grooves and hooks for assembly and a spring for sliding contact with the commutator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rail is fixed using protrusions that are squeezed by elastic inner fixtures, then the brush units can be assembled, but the protrusions are easily broken or damaged resulting in insufficient rigidity and excessive brush movement
Solution Approach 1:
Instead of making the fixtures elastic to enable assembly, the invention makes the rail itself elastic. The rail is designed with elastic deformation capability that allows it to be compressed during assembly and then resiliently press against the columns, inverting the traditional approach where the fixture provides elasticity.
Solution Approach 2:
The invention changes the material parameter of the rail from rigid to elastic. The rail is specifically designed to be elastically deformable, allowing it to compress during assembly and maintain resilient contact with the columns, thereby providing both ease of assembly and strong fixing rigidity.
2Reliability
If high hardiness materials like PPS are used for inner fixtures, then the fixtures are durable, but the protrusions are easily damaged and the rail cannot be sufficiently rigidly fixed
Solution Approach 1:
The invention inverts the source of elasticity from the fixture to the rail. Instead of using elastic fixtures that risk damaging protrusions, the rail itself is made elastic to provide the necessary deformation during assembly while the fixtures remain rigid and durable.
Solution Approach 2:
The invention extracts the elastic function from the fixture and transfers it to the rail. The fixture is designed as a rigid column structure that provides durable support, while the rail provides the elastic deformation capability needed for assembly and resilient contact.
3Ease of manufacture
If the fixing construction uses elastic deformation of inner fixtures, then assembly is possible, but the construction cannot endure high temperature
Solution Approach 1:
The invention changes the material parameter of the rail to be elastically deformable, allowing assembly through compression. The rail's elastic properties enable it to be compressed during assembly and then resiliently press against the columns, providing both assembly capability and high-temperature resistance.
Solution Approach 2:
Instead of using elastic fixtures that fail at high temperatures, the invention makes the rail itself elastic. This inversion allows the fixing construction to endure high temperatures while maintaining assembly capability through the rail's resilient deformation.
4Shape
If the rail cannot elongate in the radial direction, then the structure is compact, but the protrusions are easily broken and the rail is not sufficiently rigidly fixed
Solution Approach 1:
The invention changes the mechanical parameter of the rail from rigid to elastic in the radial direction. The rail is designed to be elastically deformable radially, allowing it to compress during assembly and resiliently press against the columns, while maintaining structural compactness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the rigidity and stability of the brush assembly, preventing damage and excessive movement, while allowing for secure assembly and operation at higher temperatures, improving yield and suitability for high-power motors.
Implementation Method 1
a spring mounted around the rail
Implementation Method 2
the closed end of the guide rail being engaged with the first fixture, the second fixture comprising two columns spaced from each other, each of the columns having a slot in a top end thereof, and a protrusion extending from a lateral side of each slot into the corresponding slot, the wings being respectively locked in the slots by the protrusions
Data Source
AI summary
An electric power steering assembly includes a motor which includes a brush assembly. The brush assembly includes a brush base, a plurality of brush units and a plurality of fixing units for fixing the brush units to the brush base. The brush unit includes a brush, a guide rail and a spring. The rail includes two guiding arms, a closed end interconnecting the guiding arms and wings extending from free ends of the guiding arms. Grooves in the brush receive the guiding arms. The fixing unit includes a first fixture and a second fixture. The closed end of the guide rail engages the first fixture. The second fixture includes two columns spaced from each other. Each column defines a slot in a top end. Protrusions extend from a side of each slot to lock the wings in the slots.