Brush Holder Segmentation for DC Motor Miniaturization
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Solution Overview
Problem
Existing brush holders with integrally molded designs face challenges in miniaturization due to interference between the brush retaining and connector portions, and require separate molds for different connector positions, leading to increased complexity and cost.
Innovation Solution
A brush holder design featuring a retaining member and base member with positioning portions that prevent movement, allowing for flexible placement of the connector portion relative to the brush retaining portion, enabling miniaturization and reducing mold requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brush holder is designed as an integrally molded object, then manufacturing simplicity is improved, but miniaturization becomes difficult due to interference between the slide core and connector portion
Solution Approach 1:
The brush holder is divided into two separate parts: the retaining member (molded with the cylindrical brush retaining portion) and the base member (molded with the connector portion). This segmentation allows each part to be molded independently without interference, enabling miniaturization while maintaining integral molding benefits for each component.
2Ease of manufacture
If the distance between the brush retaining portion and connector portion is increased to avoid interference, then molding feasibility is improved, but size reduction becomes difficult
Solution Approach 1:
By separating the brush holder into retaining member and base member, each can be molded with optimal dimensions without requiring excessive distance between features. The retaining member can be compact cylindrical while the connector portion resides on the separate base member, eliminating the need for large spacing.
Solution Approach 2:
The retaining member acts as an intermediary between the brush retaining portion and the connector portion. It provides the necessary structural connection while allowing the connector to be positioned on the base member, enabling compact overall design without molding interference.
3Adaptability or versatility
If different connector positions are used for different brush holders, then adaptability is improved, but mold requirements increase leading to higher complexity
Solution Approach 1:
The brush holder is segmented into retaining member and base member. The base member can be molded in different configurations to accommodate various connector positions, while the retaining member remains standardized. This allows adaptability through base member variation without requiring different molds for the critical retaining portion.
Solution Approach 2:
The retaining member is designed as a universal component that can be used across different brush holder applications. The base member serves as the adaptable element that can be configured for different connector positions, allowing one mold for the retaining member to serve multiple purposes while accommodating variability.
Data Source
AI summary
A gear housing accommodates a worm shaft. A brush holder includes a base member and a retaining member loosely fitted to the base member. The base member is located between the gear housing and the retaining member. The retaining member retains a first brush and a second brush. The retaining member has a pair of positioning poles, and the gear housing has a pair of positioning projections. The positioning poles and the positioning projections are engaged with each other so as to prevent the retaining member from being moved in a direction perpendicular to the axial direction of the rotary shaft.