Brush Module Assembly With Inclined Retaining Tab Release
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Solution Overview
Problem
Existing brush modules for electric motors face difficulties in assembly due to the spring force pushing the brush out of the holder, making precise positioning challenging and requiring additional steps to release the brush for contact.
Innovation Solution
A brush module with a U-shaped sheet metal bracket and laterally protruding fastening lugs, where the fastening lug is inclined by an angle α to rest on the mounting surface, allowing the brush to be released and moved into contact position without additional attachment means, simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brush is held in the brush holder by spring force, then the brush can maintain electrical contact with the slip ring, but the brush is pushed out of the brush holder making precise positioning difficult
Solution Approach 1:
The brush is pre-positioned and fixed in the brush holder using the retaining tab engagement with the through-opening before mounting. This preliminary fixing action allows precise positioning of the brush holder on the mounting surface without the brush being pushed out by spring force during the positioning process.
Solution Approach 2:
The retaining tab acts as an intermediary element between the mounting tab and the brush. It provides a mechanical locking mechanism that holds the brush in place while allowing the mounting tab to be inclined at angle α for easy mounting, thus mediating between the spring force and the positioning requirement.
2Reliability
If additional fasteners are used to lock the brush in position, then the brush can be held in the brush holder, but additional steps are required to remove fasteners or release the brush after mounting
Solution Approach 1:
The retaining tab function is merged with the mounting tab structure. The same mounting tab that provides mechanical attachment to the mounting surface also provides brush retention through its retaining tab extension. This eliminates the need for separate fasteners and simplifies the assembly process.
Solution Approach 2:
The mounting tab structure serves dual purposes: it both mounts the brush holder to the surface and retains the brush in position. The system is self-sufficient, requiring no additional fasteners or release mechanisms, as the inclined mounting tab automatically provides both functions.
3Ease of operation
If the mounting tab is inclined at angle α, then the brush can be automatically released into contact position during mounting, but the mounting tab must be precisely angled to function correctly
Solution Approach 1:
The mounting tab is designed with a specific inclination angle α as a geometric parameter. This angular parameter enables the automatic release function: when the mounting tab is installed at the correct angle, the retaining tab naturally moves out of the through-opening, releasing the brush into contact position without requiring additional operations.
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a brush module (10) for an electric machine and to a method for assembling such a brush module, the brush module having a brush (13) for electrically contacting a slip ring, the brush module having an assembly device (12) and a brush holder (11) for receiving and holding the brush, the assembly device being formed from a U-shaped sheet-metal bracket (17) which overlaps the brush holder, the sheet-metal bracket having laterally protruding fastening tabs (18) for fastening the brush holder to an assembly surface (19), a through-opening (25) being formed in the brush holder, into which through-opening a retaining tab which is formed on a fastening tab of the sheet-metal bracket engages and holds the brush in a retained position (24) in the brush holder in a form-fitting manner, the fastening tab with the retaining tab being formed in a manner inclined by an angle a relative to the assembly surface of the brush holder.