Brush-Commutator Aging for Low-Noise Motor Assembly
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Solution Overview
Problem
In motors with brushes, the initial contact state between the brush and commutator is unstable, leading to noise and current ripple due to mechanical friction and assembly tolerance, which existing aging methods fail to efficiently address.
Innovation Solution
A motor manufacturing method and system that forms a carbon layer on the commutator surface by applying voltage to the brush and rotating the armature and commutator without a magnetized magnet, allowing high-speed aging without induced electromotive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brush and commutator are assembled in the initial state, then the assembly is complete, but the contact state is unstable causing noise and current ripple
Solution Approach 1:
The patent applies a preliminary aging process by rotating the motor at a predetermined speed for a predetermined time period before normal operation. This preliminary action stabilizes the contact state between the brush and commutator surface, preventing noise and current ripple generation during subsequent normal operation.
2Reliability
If conventional aging methods are used to stabilize the brush-commutator contact, then the contact state improves, but the aging process time is excessively long
Solution Approach 1:
The patent changes the operational parameters during the aging process by rotating the motor at a predetermined speed (different from normal operation speed) and applying specific voltage conditions. This parameter optimization accelerates the stabilization of the brush-commutator contact, achieving reliable contact state in significantly reduced time compared to conventional aging methods.
3Productivity
If high speed rotation is applied during aging, then the aging effect is maximized, but induced electromotive force from magnetized magnets interferes with the process
Solution Approach 1:
The patent performs the high-speed rotation aging process before assembling the magnetized magnets into the motor. This preliminary aging action stabilizes the brush-commutator contact under optimal high-speed conditions without the interference of induced electromotive force, which would be generated if magnets were present during rotation.
4Productivity
If the motor is disassembled to apply high current for aging, then the aging effect increases, but the manufacturing process becomes complex
Solution Approach 1:
The patent applies voltage to the brush through the normal motor terminal structure, making the aging process compatible with the existing motor design. This multi-functional approach allows the same motor structure to serve both as the final product and as the aging test platform, eliminating the need for disassembly or specialized aging equipment.
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
Maximizes aging effect and significantly shortens the aging process time by enabling high-speed rotation with high current application, eliminating the need for magnet-induced electromotive force.
Implementation Method 1
applying voltage to the brush and rotating the armature and the commutator together through rotation of the shaft
Implementation Method 2
aging a contact surface of the brush and the commutator by applying a voltage to the brush and rotating the armature and the commutator together through rotation of the shaft
Data Source
AI summary
The present disclosure relates to a method and system for manufacturing a motor in which noise and current ripple caused by mechanical friction between a brush and a commutator have been reduced. In detail, a motor manufacturing method of the present disclosure comprises the steps of: assembling a shaft, an armature fixed on the shaft to be rotatably arranged, a commutator fixed on the shaft to rotate together with the armature, and a brush contacting a portion of the surface of the commutator; applying a voltage to the brush and rotating the armature and the commutator together through the rotation of the shaft to age the surface of the commutator; and, in a magnetizing device, connecting a case including a magnetized magnet to the assembled shaft, armature, commutator, and brush.