Disk-Shaped Carbon Brush for Low Resistance Rotor Discharge
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Solution Overview
Problem
Existing discharge devices for electric currents from rotor to stator parts in machines require significant installation space and have high transition resistance, especially when dealing with fluctuating alternating voltages or currents, which can damage bearing points.
Innovation Solution
A discharge device featuring a disk-shaped carbon contact element with a circular sliding contact surface, supported by a spring mechanism and a base plate, allowing for a large sliding contact area with low transition resistance and easy installation, reducing the need for multiple contact elements and minimizing installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple carbon brushes are used to form a large contact surface, then the transition resistance decreases, but the installation space and device complexity increase
Solution Approach 1:
The contact element is segmented into a modular structure consisting of a support and a contact element that can be assembled together. The contact element itself is disk-shaped with an annular sliding contact surface, creating segments that provide extensive contact area without requiring multiple separate brush components. This segmentation allows the contact surface to be divided into functional zones while maintaining a compact overall structure.
Solution Approach 2:
The contact element transitions from traditional linear brush shapes to a disk-shaped geometry with an annular sliding contact surface. This dimensional change from one-dimensional brush contacts to two-dimensional annular contacts dramatically increases the contact surface area. The annular configuration provides a large contact perimeter that engages with the shaft's axial contact surface, achieving low transition resistance without requiring multiple brushes arranged in space.
2Force
If traditional brush holders are used for each carbon brush, then the contact force can be applied, but the installation work and space requirements increase
Solution Approach 1:
The support structure integrates multiple functions into a single component: it provides mechanical support for the contact element, applies contact force through an integrated spring mechanism, and facilitates electrical connection. This merging of functions eliminates the need for separate brush holders for each contact element. The support accommodates the disk-shaped contact element and applies axial contact force through a spring mechanism built into the support structure itself, reducing the number of parts and simplifying installation.
Solution Approach 2:
The support is designed as a universal component that can accommodate disk-shaped contact elements with annular sliding contact surfaces. The spring mechanism within the support universally applies contact force to maintain electrical connection. This universal design allows the same support structure to be used regardless of the specific current requirements, as the annular contact surface can provide the necessary contact area for various current levels without requiring different holder configurations.
3Device complexity
If fiber or wire meshes are used instead of carbon brushes, then the installation space is reduced, but the transition resistance increases due to small contact surface
Solution Approach 1:
The contact element uses a disk-shaped geometry with an annular sliding contact surface, transitioning from the thin, two-dimensional structure of fiber or wire meshes to a three-dimensional disk form. This dimensional change creates a large contact perimeter in the annular configuration that engages with the shaft's axial contact surface. The annular contact surface provides extensive contact area comparable to multiple brushes, achieving low transition resistance while maintaining a compact single-element structure that requires minimal installation space.
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
The solution provides a discharge device with low transition resistance and easy installation, reducing wear and the risk of damage to bearing points, while requiring less space compared to conventional designs.
Implementation Method 1
a spring mechanism, in particular a compression spring, a disk spring, a torsion spring or a leaf spring, which is configured to apply the contact force on the contact element
Implementation Method 2
a contact force being applicable to the contact element so as to establish an electrically conductive sliding contact between a sliding contact surface of the contact element and an axial shaft contact surface of the shaft
Data Source
AI summary
A discharge device for discharging electric currents from a rotor part of a machine, in particular a rotor part with a shaft, into a stator part, the discharge device having a contact element, a support and a spring mechanism, the support being connectable to a stator part in an electrically conductive manner, the contact element being predominantly made of carbon, the contact element being accommodated on the support in an axially movable manner and connected to it in an electrically conductive manner, a contact force applicable to the contact element by the spring mechanism so as to establish an electrically conductive sliding contact between a sliding contact surface of the contact element to establish the sliding contact, and an axial shaft contact surface of the shaft, wherein the contact element is disk-shaped, the sliding contact surface being at least annular and disposable coaxially relative to the shaft contact surface.