Brush Holder Segmentation for DC Motor Miniaturization
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Solution Overview
Problem
The existing brush holders for direct-current motors face challenges in miniaturization due to interference between the brush retaining and connector portions during molding, and require separate molds for each position configuration of the connector portion, leading to increased complexity and cost.
Innovation Solution
A brush holder design featuring a retaining member and a base member, where the retaining member includes brush and component retaining portions, and the base member has a connector portion, conductive member, and terminal support portions, allowing for separate molding and easy assembly, reducing size constraints and mold requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the brush holder is made as an integrally molded object, then the structure is simplified, but molding becomes difficult when the connector portion is near the cylindrical brush retaining portion due to slide core interference
Solution Approach 1:
The brush holder is divided into two separate parts: the retaining member (including brush retaining portion and component retaining portion) and the base member (including connector portion and conductive member). This segmentation allows each part to be molded independently without interference, while still achieving structural simplification through their integrated assembly.
2Ease of manufacture
If the distance between the brush retaining portion and the connector portion is increased to avoid molding interference, then molding becomes easier, but size reduction of the brush holder becomes difficult
Solution Approach 1:
By separating the brush holder into retaining member and base member, the design allows the connector portion to be positioned close to the brush retaining portion without causing molding interference. The loose fit mounting enables compact arrangement while maintaining manufacturability.
3Adaptability or versatility
If different positions of the connector portion are required for different brush holders, then adaptability is improved, but separate molds are required for each configuration increasing manufacturing complexity
Solution Approach 1:
The separation into retaining member and base member allows the connector portion to be repositioned on the base member without affecting the retaining member design. This enables different connector positions for different applications while using the same retaining member mold, reducing overall mold complexity.
Solution Approach 2:
The base member serves as a universal component that can accommodate different connector portion positions while working with the same retaining member. This multi-functionality allows a single retaining member mold to serve multiple brush holder configurations.
Data Source
AI summary
A brush holder includes a base member and a retaining member mounted on the base member. The retaining member includes a first brush retaining portion and a first coil retaining portion. A first choke coil is electrically connected to a first brush. The first choke coil includes a first coil terminal extending to the outside of the first coil retaining portion. The base member includes a connector portion, a first conductive member, and a first coil terminal support portion. The first conductive member extends from the connector portion and is electrically connected to the first coil terminal at a first connecting portion. The first coil terminal support portion supports the first coil terminal between the first connecting portion and the first coil retaining portion.