Brush Device Choke Coil Terminal Contact Stress Relief
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Solution Overview
Problem
Conventional brush devices experience noise bypass due to parasitic capacitance between terminal members and choke coils, leading to potential breakage and noise issues in compact motor applications.
Innovation Solution
The brush device design includes a choke coil with a core and winding, where the terminal member contacts the core's end surface, relieving stress and preventing noise bypass by spacing the terminal connections apart, thus reducing parasitic capacitance and noise flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal member is connected to the winding of the choke coil, then electrical connection is achieved, but stress from vibration acts on the connecting portion and may cause breakage
Solution Approach 1:
The core serves as an intermediary component between the terminal member and the winding. The terminal member contacts the core's end surface, which then transmits force to the winding through controlled contact points, protecting the welding portion from direct stress
Solution Approach 2:
The core structure is designed beforehand to absorb and distribute vibration stresses before they reach the connecting portion. The core's physical properties and geometry are predetermined to cushion impacts and reduce stress concentration at the welding joint
2Volume of moving object
If the terminal and second terminal member are located adjacent to each other to face each other, then compact layout is achieved, but parasitic capacitance is generated and noise bypasses the choke coil
Solution Approach 1:
Different regions of the device are assigned different functional qualities. The terminal members are positioned in specific locations with particular orientations to minimize parasitic capacitance while maintaining compact size. The core's geometry is optimized to create electrical isolation zones that prevent noise bypass
Solution Approach 2:
The terminal members are positioned asymmetrically relative to the core rather than symmetrically adjacent to each other. This asymmetric arrangement reduces the parasitic capacitance between terminals while maintaining effective noise filtering through the choke coil
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 effectively reduces the risk of breakage and noise bypass, enhancing the reliability and noise reduction in brush devices, particularly in compact motor setups.
Implementation Method 1
The choke coil includes a core, which is arranged on the holder, and a winding, which is wound around an outer circumference of the core and electrically connected to the brush
Data Source
AI summary
A brush device includes a holder, a brush, a choke coil, and a terminal member. The holder includes a base extending in a direction orthogonal to an axial direction of an armature. The choke coil includes a core and a winding. The core extends in the axial direction of the armature and includes a first end surface in a longitudinal direction faced toward the base of the holder and a second end surface in the longitudinal direction located at a side opposite to the first end surface. The terminal member is coupled to the holder and connected to the winding. The terminal member includes a contact portion that is in contact with the second end surface of the core.