Brush Holder Connector Separation for Motor Versatility
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Solution Overview
Problem
The existing electric motors with brushes require multiple types of brush holders with different connector specifications, leading to increased costs and complexity due to the integral formation of the connector part with the brush holder using resin, necessitating various dies and complicating the molding process.
Innovation Solution
The electric motor design separates the power-supply connector unit from the brush holder, allowing for different connector specifications to be handled by changing only the connector unit, while keeping the brush holder specifications common, thereby enhancing versatility and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector part is integrally formed with the brush holder using resin, then the structure is simplified and assembly is easier, but multiple types of brush holders with different connector specifications must be prepared, increasing costs and complexity
Solution Approach 1:
The connector part is separated from the brush holder into an independent component. The brush holder maintains a standardized design while the connector part can be independently selected or modified to match different external connector specifications, eliminating the need to create multiple brush holder variants.
Solution Approach 2:
A single standardized brush holder design is made universal by decoupling it from specific connector configurations. The brush holder serves its primary function of holding brushes and providing electrical connections, while the separate connector part adapts to various external connector types, making the brush holder applicable across multiple product variants.
2Ease of manufacture
If the connector part is integrally formed with the brush holder, then assembly is simplified, but the shape of the dies becomes complicated and the size of the die increases, resulting in increased die costs
Solution Approach 1:
The molding process is segmented into separate operations for the brush holder and the connector part. This allows each component to be molded using simpler, smaller dies optimized for their specific geometries, rather than requiring a single complex die to produce the integrated assembly.
Solution Approach 2:
While the components are manufactured separately, they are subsequently assembled together to form the complete brush holder assembly. This merging of separately manufactured components achieves the functional integration of the integral design while avoiding the manufacturing complexity of integral molding.
3Adaptability or versatility
If multiple types of brush holders with different connector specifications are prepared, then different external connector specifications can be accommodated, but the number of required dies increases, leading to increased costs
Solution Approach 1:
The connector part is segmented from the brush holder, allowing the brush holder to maintain a single standardized design. Different connector specifications are achieved by modifying or selecting different connector parts rather than creating multiple brush holder variants, thereby reducing the number of required dies to one for the brush holder.
Solution Approach 2:
The standardized brush holder is designed as a universal component that can work with various connector types. This universality is achieved by separating the connector interface from the brush holder structure, allowing a single brush holder design to serve multiple applications with different external connector specifications.
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 enables the production of electric motors with reduced costs and increased versatility by allowing the use of a common brush holder for various connector specifications, simplifying the manufacturing process and reducing the number of required dies.
Implementation Method 1
a pair of brushes is held at a brush holder mounted in the motor case. Each of the brushes is in slide contact with an outer circumference of the commutator, and when each of the brushes is connected to a power source, the current is supplied to each of the armature coils via the brushes and the commutator
Implementation Method 2
an electric motor with brush in which a current is supplied to armature coils via brushes and a commutator has been widely used as a motor body
Data Source
AI summary
General versatility of a brush holder is enhanced regarding a difference of specifications of connector parts, and costs of an electric motor with brush are reduced. A pair of brush-side connection terminals electrically connected to brushes is provided to a brush holder mounted inside a motor yoke. A connector part and a pinching part are provided in a connector unit formed separately from the brush holder, power connection terminals are provided in the connector part, and connector-side connection terminals electrically connected to the power connection terminals are provided inside the pinching part. The pinching part is disposed so as to overlap with the brush holder axially, thereby electrically connecting the brush-side connection terminals and the connector-side connection terminals, and the brushes are electrically connected respectively to the power connection terminals, and the pinching part is sandwiched and fixed between the motor yoke and a gear case.