Brush Lead Guide for Brush Holder Assembly

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Solution Overview

Problem

In electrical devices, the leads extending from brushes can interfere with the movement of the brush within the brush holder as the brush wears down, necessitating a solution to maintain the leads in a desired position to prevent interference.

Innovation Solution

A lead guide comprising a bracket with a first guide rail, a second guide rail, and a cross member is used to space the leads apart, allowing a spring to be positioned between them, ensuring the leads do not contact the brush holder and restricting free movement of the brush.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the leads are allowed to extend freely from the brush, then the brush can move freely within the brush holder, but the leads will interfere with the movement as the brush wears down

Engineering Contradiction:

Improvebrush movement freedomVSAvoidcontinuous operation

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A lead guide structure acts as an intermediary component between the leads and the brush holder. The guide includes guide rails that receive and constrain the leads, preventing them from interfering with brush movement while allowing the brush to move freely within the brush holder as it wears down.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the leads are constrained to prevent interference, then continuous operation is ensured, but the brush movement freedom is restricted

Engineering Contradiction:

Improvecontinuous operationVSAvoidbrush movement freedom

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The lead guide structure applies local constraint only where needed - the guide rails constrain the leads in specific regions to prevent interference with the brush holder, while leaving other regions free to allow natural brush movement. This localized approach maintains brush movement freedom while ensuring continuous operation.

Inventive Principle:

Principle #3Local quality

3Shape

If the spring is positioned between the leads, then the leads are spaced appropriately, but the device complexity increases

Engineering Contradiction:

Improvelead spacingVSAvoidlead guide structure

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The lead guide structure serves multiple functions simultaneously: it spaces the leads apart to prevent interference, guides the leads to maintain proper positioning, and allows the spring to be positioned between the leads for electrical contact. This multi-functionality achieves proper lead spacing without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9917408B2Brush lead guide for a brush holder assembly

Publication Date: 2018.03.13 CUTSFORTH INC

AI summary

A brush lead guide for a brush holder assembly configured to retain the leads extending from a brush in a desired position/orientation to ensure the leads do not interfere with movement of the brush within the brush holder. In some instances, the lead guide includes a first guide rail including a channel for receiving a first lead of the brush and a second guide rail including a channel for receiving a second lead from the brush. The lead guide maintains the leads in a position such that the leads are held within the width of the opening of the brush holder to ensure the leads do not interfere with movement of the brush within the brush holder during use of the brush holder assembly.