Brush Motor Rotor Terminals Reduce Wire Breakage
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Solution Overview
Problem
Conventional brush motor rotors experience wire breakage due to inertial forces and resonant state differences between the core and commutator during rotation, leading to reduced reliability and increased manufacturing complexity.
Innovation Solution
The rotor design incorporates terminals on the bobbins for wire hooking, with metal pieces extending from the commutator segments and a wiring board for electrical connection, eliminating the need to draw wires out and enhancing structural stability and manufacturing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are drawn out from bobbins to commutator segments for electrical connection, then electrical connectivity is achieved, but wire breakage occurs due to inertial force during rotation
Solution Approach 1:
The patent introduces terminals as intermediary components that remain fixed to the bobbins, eliminating the need for long wires to extend from bobbins to commutator segments. The terminals provide a stable connection point that reduces wire length and minimizes inertial stress on the wires during rotor rotation.
2Reliability
If wires are drawn out from bobbins to commutator segments, then electrical connection is established, but resonance-induced vibration causes wire breakage
Solution Approach 1:
Terminals serve as intermediary components that provide stable mounting points on the bobbins, reducing the susceptibility of wires to resonance-induced vibrations. By shortening the wire length and providing rigid attachment points, the terminals dampen vibrational effects and prevent wire fatigue and breakage.
3Reliability
If conventional hooking method is used to connect wires to commutator segments, then manufacturing process is simple, but wire breakage occurs during rotation
Solution Approach 1:
The introduction of terminals adds a component layer between wires and commutator segments, which increases structural complexity but significantly improves reliability. The terminals provide robust mounting points that prevent wire breakage, justifying the additional complexity through enhanced durability and reduced maintenance.
4Manufacturing precision
If long wires are used to connect bobbins to commutator segments, then electrical connectivity is achieved, but manufacturing precision is reduced due to wire positioning difficulties
Solution Approach 1:
Terminals act as fixed intermediary components mounted on the bobbins, providing precise and repeatable connection points for wires. This eliminates the need for complex wire routing and positioning during manufacturing, significantly improving manufacturing precision while reducing the effective wire length required for electrical connection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces wire breakage, stabilizes electrical connections, and simplifies manufacturing by automating the connection process, while improving vibration resistance and heat management.
Implementation Method 1
When an electric current flows through a coil, the coil generates a magnetic field. Magnetic forces among the coils of the rotor and magnets disposed on the stator cause the rotor to rotate with respect to the stator.
Data Source
AI summary
A rotor includes coils that are formed by winding wires around bobbins of a core, terminals which are arranged on the bobbins and to which end portions of the wires are hooked, and a commutator arranged at an end portion of the core on a side where the terminals are arranged. The terminals and commutator segments of the commutator are electrically connected via metal pieces extending from the commutator segments and via a wiring board.