Brush Device Axial Conductor Routing Through Helical Spring
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Solution Overview
Problem
Existing brush devices for electric machines face challenges in cost-effectively connecting electrical conductors to brushes without hindering the function of helical springs or risking conductor damage due to bending.
Innovation Solution
The brush device design includes a stop with a through opening in the brush box, allowing the electrical conductor to route through the helical spring and into a connection at the end of the brush box, with a lateral deflection space in the brush holder for the conductor to deflect elastically without impairing the helical spring's function, and a positive locking connection to the brush's back side for reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrical conductor is laterally attached to the brush and routed between the brush boxes, then the conductor can be connected to the brush, but the manufacturing cost increases and the conductor may become seized when the helical spring is pressed together
Solution Approach 1:
The patent changes the routing dimension of the electrical conductor from lateral routing between brush boxes to routing through the helical spring along its axial direction. This dimensional change allows the conductor to pass through the spring's central opening, avoiding the need for lateral attachment between brush boxes and eliminating the risk of the conductor becoming seized in the spring windings.
Solution Approach 2:
The helical spring serves as an intermediary element that the electrical conductor passes through. Instead of the conductor being attached laterally to the brush, it is routed through the spring itself, which acts as a guide and protective channel. This intermediary role of the spring allows the conductor to maintain electrical contact while avoiding direct lateral attachment that would increase manufacturing complexity and risk of seizure.
2Ease of manufacture
If the electrical conductor is routed laterally to the brush, then the connection can be made, but the conductor may be bent and damaged in certain sections
Solution Approach 1:
The patent changes the conductor routing from lateral attachment to axial routing through the helical spring. This dimensional change eliminates sharp bends and lateral constraints that would compromise conductor integrity. The conductor passes through the spring's central opening in a straight or gently curved path, avoiding the bending and stress concentrations that occur with lateral attachment methods.
3Reliability
If the stop is configured to brace the helical spring, then the spring function is maintained, but the conductor cannot be routed on the back side of the brush
Solution Approach 1:
The helical spring serves multiple functions simultaneously: it provides the bracing force to maintain brush contact pressure, and it serves as a routing channel for the electrical conductor through its central opening. This multi-functionality eliminates the need for separate conductor routing paths and simplifies the overall device structure while maintaining both spring function and conductor integrity.
Solution Approach 2:
The helical spring acts as an intermediary structure that accommodates both its bracing function and the conductor routing function. The central opening of the spring mediates the passage of the conductor while the outer structure maintains the bracing force. This intermediary role allows the stop to brace the spring effectively while enabling conductor routing through the spring rather than requiring separate routing paths.
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 design reduces manufacturing costs and prevents conductor damage by allowing elastic deformation of the conductor without affecting the helical spring's function, ensuring a reliable and cost-effective connection.
Implementation Method 1
the brushes are mounted in the respective brush box in a displaceable manner and wherein respectively one helical spring can be braced/is pretensioned in the respective brush box between one of the brushes and a stop
Implementation Method 2
a lateral deflection space for the electrical conductor is configured in the brush holder between the connection and the stop. The electrical conductor can deflect into said deflection space when the respective brush is being displaced by elastic deformation
Data Source
AI summary
The invention relates to a brush device, in particular for an electric machine, comprising at least one brush holder which has at least two brush boxes for receiving in each case one brush, wherein the brushes are mounted in a displaceable manner in the respective brush box and wherein a helical spring can be braced/is pretensioned in each case between one of the brushes and a stop in the respective brush box, and comprising at least two elastically deformable electrical conductors which are each connected with an end thereof to one of the brushes.