Brush Device With Bent Arm For Motor Commutator
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Solution Overview
Problem
Conventional small-sized motors face issues with short brush arm length, leading to phase shift, unstable contact pressure, and deformation during assembly, due to internal terminal structures that limit brush arm extension and cause permanent set, and external terminals contacting receptacle terminals in a sliding-up direction, resulting in deformation.
Innovation Solution
The design includes brush devices with inclined brush arms and bases, where the brush arm is bent through a base hole to increase length, allowing external terminals to contact receptacle terminals in a sliding-down direction, reducing phase shift and deformation, and improving assembly accuracy by symmetrical positioning of brush opening holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the brush arm length is increased to reduce phase shift and improve contact stability, then the brush arm cannot be extended due to the internal terminal structure using the receptacle terminal
Solution Approach 1:
The brush arm is bent into a curved configuration rather than extending linearly, allowing it to achieve greater effective length while accommodating the receptacle terminal structure. The brush arm extends from the brush base, bends at a first position, and then extends again at a second position, creating a multi-dimensional path that resolves the length constraint.
Solution Approach 2:
Instead of the receptacle terminal extending from the brush base in the conventional manner, the receptacle terminal is configured to extend from a position away from the brush base, with the brush arm bending around this inverted arrangement. This inversion allows the brush arm to achieve greater length without interference.
2Ease of operation
If external terminals are inserted with tip end portions contacting receptacle terminals in a sliding-up direction, then the receptacle terminals may deform
Solution Approach 1:
The receptacle terminal is configured to extend in a direction away from the brush base, which inverts the conventional arrangement. This inversion changes the sliding direction during terminal insertion from upward to downward, preventing the deformation that occurs with upward sliding contact.
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
This configuration increases brush arm length to reduce phase shift and pressure variation, prevents deformation, and enhances assembly accuracy by reducing cumulative dimensional errors, ensuring stable contact and improved moldability.
Implementation Method 1
a carbon brush to come into sliding contact with a commutator
Implementation Method 2
the brush arms deform when the brushes are opened during assembly of the motor (the brush arms are apt to cause permanent set)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Each of the paired brush devices includes a brush in sliding contact with a commutator, a brush arm holding the brush, and a brush base to which the brush arm is fixed and which has a base hole. The pair of brush devices are disposed such that a line connecting the centers of the pair of brushes inclines in relation to a line connecting the centers of a pair of magnets. Each of the brush arms of the brush devices is disposed on the outside of the corresponding brush base at a location where the brush arm is fixed to the brush base, and one of the brush arms is bent from the outside of the corresponding brush base toward the inside thereof while being passed through the base hole to intersect the brush base.