Brush Restricting Pin Prevents Detachment in Rotary Electric Equipment
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Solution Overview
Problem
During the assembly and disassembly of controller-integrated electric rotating machines, brushes frequently break away from their holders, leading to failures and reduced workability.
Innovation Solution
The integration of brush restricting pins into the assembly process, which are inserted into specific holes to prevent the brush from detaching from the rotary shaft, combined with a structured assembly and disassembly method that ensures the brush remains secure, enhancing the workability of both processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brush is held in the brush holder during assembly, then the brush can be positioned correctly, but the brush may break away from the brush holder to the rotary shaft side during assembly and disassembly
Solution Approach 1:
The brush restricting pin is inserted into the brush restricting pin insertion hole before the assembly of the front side semi-manufactured assembly and rear side semi-manufactured assembly. This preliminary action prevents the brush from breaking away during the subsequent assembly process, resolving the contradiction between brush retention and assembly workability.
Solution Approach 2:
The brush restricting pin acts as an intermediary component that temporarily connects and secures the brush to the brush holder during assembly. This intermediary element prevents direct contact and potential damage between the brush and surrounding components, enabling smooth assembly while maintaining brush retention.
2Reliability
If the brush is securely held during operation, then electrical contact is maintained, but the brush may get stuck in the groove between the rear side bearing and sensor rotor during disassembly
Solution Approach 1:
The sensor rotor is detached from the rotary shaft before disassembling the front side semi-manufactured assembly from the rear side semi-manufactured assembly. This preliminary action prevents the brush from getting stuck in the groove between the rear side bearing and sensor rotor during disassembly, resolving the contradiction between brush positioning and disassembly workability.
Solution Approach 2:
The disassembly sequence is inverted from the typical approach by first removing the control unit assembly and detaching the sensor rotor before attempting to separate the semi-manufactured assemblies. This reversed sequence eliminates the risk of brush entanglement in the groove, enabling easy disassembly while maintaining proper brush positioning.
Data Source
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AI summary
A control unit assembly A is located at a rearmost side, a brush unit assembly C is located at a frontmost side, and a power unit assembly B is located between the control unit assembly and the brush unit assembly, respectively. The control unit assembly, the brush unit assembly and the power unit assembly are incorporated in a rear bracket 5. The rear bracket, the control unit assembly, the power unit assembly, and the brush unit assembly are integrated to configure a rear side semi-manufactured assembly D. In a controller-integrated electric rotating machine configured to assemble a front side semi-manufactured assembly E formed from an electric rotating machine main body 1 and a front bracket 4 with the rear side semi-manufactured assembly D, a series of brush restricting pin insertion holes 24 are disposed from a rear side end surface of the control unit assembly through the brush. Assembling workability is improved without failures in assembling work which occur due to breaking away of a brush from a brush holder to the rotary shaft side.