Brush-holder Recess for Simultaneous Unit Insertion
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Solution Overview
Problem
Existing brush-holders for electric machines require complex manufacturing processes involving multiple assembly stations and steps, including the need to rotate the housing for different unit fittings and individual insertion of EMC units, which increases manufacturing costs and time.
Innovation Solution
A brush-holder design with a recess that allows for the simultaneous insertion and electrical bonding of multiple units from the same side, using a ceramic printed circuit board with SMD components and positioning elements for cost-effective production and simplified assembly, reducing the number of necessary steps to two.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the housing is provided with a recess that allows simultaneous insertion and bonding of multiple units from the same side, then the manufacturing complexity is reduced and assembly time is shortened, but the recess design requires precise positioning elements and through-openings that increase housing design complexity
Solution Approach 1:
The recess is segmented into multiple bonding regions, each accessible through its own through-opening, allowing independent access to different units. This segmentation enables simultaneous multi-point bonding operations from the same side without interference, resolving the contradiction by organizing complexity into manageable sections.
Solution Approach 2:
The recess extends in the depth direction of the housing, creating a three-dimensional workspace that accommodates multiple units at different positions. This dimensional approach allows units to be arranged along the depth axis while maintaining front-side accessibility, transforming a two-dimensional surface problem into a three-dimensional solution.
2Ease of manufacture
If all units are inserted and bonded from the same side, then the number of assembly steps is reduced to two, but the recess must be designed as a through-opening which may compromise housing integrity
Solution Approach 1:
The recess is divided into multiple bonding regions with separate through-openings, allowing localized access without compromising the entire housing structure. Each through-opening is minimized in size and strategically positioned, maintaining housing integrity while enabling simplified assembly operations.
Solution Approach 2:
The housing structure is differentiated into regions: areas with through-openings for access, areas with positioning elements for unit placement, and areas maintaining full housing integrity. This local quality approach ensures that structural weaknesses are confined to specific locations while the overall housing maintains sufficient strength.
3Manufacturing precision
If positioning elements are provided in the recess to hold units in predetermined positions, then manufacturing precision is improved, but the number of components and assembly complexity increases
Solution Approach 1:
The positioning elements are integrated directly into the housing structure rather than being separate components. This merging eliminates the need for additional positioning parts while maintaining precise unit positioning, as the housing itself provides the positioning function through its molded features.
Solution Approach 2:
The housing serves multiple functions: it provides structural enclosure, creates the recess workspace, provides positioning elements for unit placement, and maintains electrical insulation. This multi-functionality reduces the need for separate positioning components, resolving the contradiction between precision and complexity.
Data Source
Figure 3~5
Figure 6
Figure 7
AI summary
The present invention relates to a brush-holder (5) for an electric machine (1) such as, for example, an electric motor and/or a generator, with a housing (7) having a brush support (8) for the accommodation of at least one brush (9) for electrically contacting of rotor windings (6) of the machine (1), wherein the housing (7) is provided, on an installation side (11), with a recess (12) for the accommodation of electric and/or electronic units (13). The manufacture of the brush-holder (5) is simplified, when these units (13) are inserted into the recess (12) from the installation side (11), such that they can be electrically bonded from the installation side (11).