Brush Holder Integration via Elastic Abutment in Electric Motors
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Solution Overview
Problem
Conventional methods for integrating a brush holder with a yoke and bracket in electric motors require screws, leading to increased complexity, weight, and size due to the need for convex and concave portions on the outer circumference, and external fitting of tubular elastic members, which complicates operation and reduces productivity.
Innovation Solution
A brush holder design with a cylindrical yoke, bracket, and brush holder that uses a ring-shaped abutting surface and elastic members to securely hold the brush holder without screws, featuring a flat ring-shaped elastic member with ribs and projections for stable fixation and sealing, allowing for reduced size and improved fitting quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are used to integrate the brush holder, yoke and bracket, then the integration is secure, but the structure becomes complicated and the number of components increases
Solution Approach 1:
The brush holder, yoke, and bracket are integrated into a single unified structure without using separate fastening components like screws. The brush holder is formed as an integral part of the yoke-bracket assembly, eliminating the need for additional fastening hardware and simplifying the overall structure while maintaining secure integration.
Solution Approach 2:
The yoke-bracket assembly serves multiple functions simultaneously: it provides structural support, acts as a mounting bracket, and integrates the brush holder function. This multi-functional design eliminates the need for separate components and reduces overall device complexity while maintaining reliability.
2Device complexity
If convex portions are formed on the outer circumference of the brush holder and tubular elastic members are externally fitted, then the brush holder can be held without screws, but the operation becomes troublesome and productivity decreases
Solution Approach 1:
The elastic member is integrated directly into the mold as a single unit with the brush holder, rather than being a separate component that needs to be fitted externally. This merging of the elastic member with the brush holder structure eliminates the need for separate assembly operations and significantly improves productivity.
Solution Approach 2:
The elastic member is pre-formed and positioned within the brush holder structure during the molding process itself, rather than being added in a subsequent assembly step. This preliminary action during manufacturing eliminates the need for separate fitting operations and enhances assembly efficiency.
3Reliability
If concave portions are formed on the outer circumference of the yoke or housing for fitting, then the brush holder can be held, but the outside diameter increases which goes against weight and size reduction
Solution Approach 1:
Instead of forming concave portions on the outer circumference of the yoke (radial dimension), the elastic member is integrated into the brush holder structure itself. This shifts the holding mechanism to the brush holder dimension, allowing the yoke to maintain its original outer diameter and reducing overall device size and weight.
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
The solution enables reliable fixation and sealing of the brush holder, reduces size and weight, simplifies the integration process, and enhances productivity by eliminating the need for external tubular elastic members and special shapes, while maintaining stable holding and sealing functions.
Implementation Method 1
a bracket-side elastic member which is interposed between the brush holder and the bracket; the abutting surface is formed as a holding portion that is pressed to the yoke by the bracket via the bracket-side elastic member
Implementation Method 2
a rib is provided on the bracket-side elastic member in a protruding condition so as to make contact with the abutting surface
Data Source
AI summary
An electric motor includes a cylindrical yoke with a bottom; a bracket that covers an opening of the yoke; and a brush holder. The brush holder includes a brush housing portion, with the brush housing portion having three side piece portions, excluding a bottom piece portion, integrally formed; a first disk portion; and a second disk portion. The first disk portion and the second disk portion are integrated with the bottom piece portion of the brush housing portion. A ring-shaped abutting surface and the bottom piece portion of the brush housing portion are formed on a bracket-side disk surface of the brush holder. The abutting surface is formed as a holding portion that is pressed to the yoke by the bracket via a bracket-side elastic member.