Brush Device Segmented Assembly for DC Motor Productivity
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Solution Overview
Problem
Conventional brush assembly methods for six-pole magnet type DC motors are inefficient, leading to poor assemblability and low productivity due to the difficulty in simultaneously inserting and securing all brushes into the brush holders from the inside radial direction.
Innovation Solution
The brush device includes positive and negative side brush sub-assemblies with convex portions and slits that engage each other, allowing for easier assembly by increasing the assembling space and eliminating the need for separate positioning regulators, thus simplifying the assembly process and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brushes are inserted into brush holders one by one from inside in radial direction, then brushes can be securely held, but assembling work takes time and productivity is low
Solution Approach 1:
The brush assembly is segmented into multiple brush holders arranged circumferentially, each capable of independent brush insertion from the outside. This segmentation allows parallel assembly operations rather than sequential insertion, significantly improving productivity while maintaining secure brush holding through each individual holder's structure.
Solution Approach 2:
Instead of inserting brushes from inside the radial direction as in conventional designs, this invention inverts the insertion direction to from outside in radial direction. This inversion enables easier access for brush insertion and securing operations, allowing workers to efficiently assemble brushes into holders without complex internal access requirements.
2Productivity
If multiple brush holders are assembled simultaneously, then productivity improves, but assemblability deteriorates due to interference
Solution Approach 1:
Each brush holder is designed with locally optimized features including circumferentially oriented insertion slots and positioning structures that accommodate simultaneous assembly. The local quality of each holder's geometry ensures that multiple holders can be assembled in parallel without mutual interference, as each holder's assembly interface is independently configured.
Solution Approach 2:
The invention utilizes circumferential arrangement of brush holders around the commutator, adding a rotational dimension to the assembly process. This dimensional arrangement allows multiple holders to be positioned at different angular locations, enabling simultaneous assembly operations without spatial interference between adjacent holders.
3Device complexity
If conventional brush assembly method is used, then structure is simple, but assembly time increases and labor requirements increase
Solution Approach 1:
Brush holders are pre-configured with insertion slots and positioning features before assembly. This preliminary preparation of the holders allows brushes to be quickly inserted and secured without complex alignment procedures during final assembly, significantly reducing assembly time and labor requirements while maintaining structural simplicity.
Data Source
AI summary
In order to facilitate the assembly of the brush assembly and to improve the productivity, the brush device includes a positive side brush subassembly having a positive side brush for feeding a commutator, a positive side brush holder for holding the positive side brush, and a positive side plate to which the positive side brush holder is attached, and a negative side brush subassembly having a negative side brush for feeding the commutator, a negative side brush holder for holding the negative side brush, and a negative side plate to which the negative side brush holder is attached. The positive side brush subassembly and the negative side brush subassembly are combined with each other.