Brush Module Assembly With Retaining Tab for Precise Mounting
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Solution Overview
Problem
Existing brush modules for electric machines face difficulties in mounting due to the spring force pushing the brush out of the holder, making precise positioning challenging and requiring additional steps to secure the brush in contact position.
Innovation Solution
A brush module with a U-shaped sheet-metal bracket mounting device featuring inclined fastening tabs that engage with the brush holder, allowing the brush to be retained in a form-fitting manner and released without additional steps during mounting, enabling simplified assembly by pivoting the retaining tab to align with the mounting surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brush is exposed to spring force to move toward the slip ring, then the brush is pressed on the slip ring for forming an electric contact, but the brush is pushed out of the brush holder making mounting difficult
Solution Approach 1:
The brush is pre-retained in the brush holder by the retaining tab engaging in the access opening during mounting. This preliminary retaining action prevents the brush from being pushed out before mounting is complete, while still allowing the spring force to be applied for eventual contact with the slip ring.
Solution Approach 2:
The retaining tab acts as an intermediary element between the brush and the brush holder during mounting. It temporarily holds the brush in position, mediating between the spring force that wants to push the brush out and the need to keep the brush secured during the mounting process.
2Ease of operation
If fasteners are used to lock the brush in a retaining position, then the mounting is facilitated, but the fasteners must be removed or the brush must be released in an additional work step after mounting
Solution Approach 1:
The retaining tab and the mounting process are merged into a single integrated feature. The retaining tab is formed as part of the mounting device structure, combining the functions of mounting and brush retention into one element, eliminating the need for separate fasteners and additional release steps.
Solution Approach 2:
The mounting device performs the dual function of both mounting the brush holder and retaining the brush automatically. When the mounting device is installed, it self-secures the brush in the retaining position without requiring separate fasteners or additional operations.
3Ease of operation
If the fastening tab is inclined at an angle relative to the mounting surface, then the retaining tab can release the brush during mounting, but the fastening tab must be pressed against the mounting surface to remove the inclination
Solution Approach 1:
The fastening tab transitions from an inclined state during mounting to a pressed state against the mounting surface. This dynamic change in position and orientation allows the retaining tab to release the brush during the inclined phase, while the final pressed phase secures the mounting device in place.
Solution Approach 2:
The inclination of the fastening tab during the mounting process creates the necessary condition for the retaining tab to release the brush. This preliminary inclined position is intentionally designed to enable brush release before the final mounting compression is applied.
Data Source
AI summary
The invention relates to a brush module (10) for an electric machine and to a method for mounting such a brush module, the brush module having a brush (13) for forming an electric contact with a slip ring, the brush module having an mounting device (12) and a brush holder (11) for accommodating and holding the brush, the mounting device being realized as a U-shaped sheet-metal bracket (17) which engages over the brush holder, the sheet-metal bracket having laterally protruding fastening tabs (18) for fastening the brush holder to an mounting surface (19), an access opening (25) being formed in the brush holder, a retaining tab, which is formed on a fastening tab of the sheet-metal bracket, engaging in the access opening and holding the brush in the brush holder in a retaining position (24) in a form-fitting manner, the fastening tab having the retaining tab being inclined at an angle α relative to the mounting surface of the brush holder.