Carbon Brush Holder With Embedded Metal Frame
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Solution Overview
Problem
Conventional carbon brush holders in electro-mechanical systems often have an excessively large included angle between the main and branch frames, leading to gaps between the carbon brushes and conductive slip rings, which obstructs the transmission of electric current or signals, especially in miniaturized assemblies with shorter intervals between insulating rings.
Innovation Solution
A carbon brush holder design featuring an insulating base with specific slots and a metal brush frame with a main frame and branch frames, where the branch frames are supported and fixed to ensure precise contact with the conductive ring of a slip ring assembly, using a stamping and bending process to form the metal frame and embedding it within a circular groove of the slip ring assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the metal brush frame is formed by punching process, then the manufacturing is simple, but the included angle between main frame and branch frames becomes too large causing gaps
Solution Approach 1:
The patent applies preliminary action by pre-forming the metal brush frame with the exact required included angle through stamping and bending processes before assembly. The frame is prepared in advance with precise geometric parameters, ensuring the branch frames are positioned at the correct angle relative to the main frame, thereby preventing gaps between carbon brushes and slip rings before the actual assembly occurs.
2Adaptability or versatility
If the branch frames are not precisely positioned, then the structure is more flexible, but the carbon brushes fail to contact the conductive slip ring accurately
Solution Approach 1:
The patent applies segmentation by dividing the metal brush frame into distinct components: a main frame and separately formed branch frames. This segmentation allows each component to be manufactured and positioned independently with precise control over their relative orientations. The branch frames can be accurately positioned at specific angles to ensure reliable carbon brush contact with the conductive slip ring, while the overall structure maintains necessary flexibility for assembly and adjustment.
3Ease of manufacture
If the included angle between main frame and branch frames is large, then the assembly is easier to manufacture, but gaps appear between carbon brushes and conductive slip ring
Solution Approach 1:
The patent applies parameter changes by precisely controlling the included angle parameter between the main frame and branch frames through optimized stamping and bending processes. Instead of using a large included angle that would ease assembly but create gaps, the invention adjusts the angle parameter to an optimal value that ensures both manufacturability and precise contact between carbon brushes and the conductive slip ring, eliminating gaps while maintaining assembly feasibility.
Data Source
AI summary
A carbon brush holder is provided, which includes an insulating base, a metal brush frame, and two carbon brushes, wherein the insulating base includes a first base and two second bases correspondingly engaging with two matching portions of the first base respectively; the first base has a first slot having a straight section and two winding sections respectively connected to two ends of the straight section and each of the second bases has a second slot, and a protrusion is formed on a slot wall thereon. The metal brush frame includes a main frame and two branch frames respectively connected to two ends of the main frame, wherein the main frame is embedded in the first slot; the two branch frames are embedded in the two second slots, and are connected to two carbon brushes respectively, to thereby provide an improved contact between the two carbon brushes and a slip ring assembly.