Dual Spring Motor Brush Housing for Vibration Stability
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Solution Overview
Problem
Existing motor brush card assemblies face issues with insufficient force retention, leading to displacement of brushes during vibrations, which affects the reliability of electrical connections between the brush and the commutator.
Innovation Solution
A motor design incorporating a first helical torsion spring and a second leaf spring, where the first spring pushes the brush along a first direction towards the commutator, and the second spring, integrated with the brush housing part, pushes the brush along a second direction intersecting the first, ensuring secure holding between the brush and the holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single pressurizing member (coil spring) is used to apply force to the brush, then the structure is simple, but the force magnitude may be insufficient and the brush may be displaced during vibrations
Solution Approach 1:
The single pressurizing member is divided into two separate springs: a first spring (coil spring) that applies force in a first direction toward the commutator, and a second spring (leaf spring) that applies force in a second direction intersecting the first direction. This segmentation allows each spring to contribute to brush stabilization in different directions, improving overall positioning reliability while maintaining reasonable structural complexity
Solution Approach 2:
The force application is extended from a single direction to two intersecting directions by introducing the second spring perpendicular to the first spring's force direction. This dimensional expansion creates a more robust holding mechanism that resists displacement from multiple directions, including vibrational forces
2Reliability
If the brush is held firmly between the holder and the second spring, then displacement due to vibrations is prevented, but the brush needs to maintain contact pressure with the commutator throughout its service life
Solution Approach 1:
The first spring is designed as a helical torsion spring that can rotate about its longitudinal axis, allowing dynamic adjustment of the brush's angular position. This rotational freedom enables the brush to self-adjust and maintain optimal contact with the commutator surface throughout its service life, accommodating wear and dimensional variations while maintaining stable electrical contact
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 configuration effectively secures the brush in place, enhancing contact pressure and reducing wear, while allowing for increased service life by maintaining contact even as the brush wears down, and prevents displacement due to vibrations.
Implementation Method 1
a first spring which pushes the brush along a first direction toward the commutator
Implementation Method 2
a second spring which pushes the brush along a second direction intersecting the first direction
Data Source
AI summary
A motor includes a commutator, a brush, a first spring, a second spring, and a holder. The brush is configured to come into contact with the commutator to be electrically connected to the commutator. The first spring is configured to push the brush along the first direction toward the commutator. The second spring pushes the brush along a second direction intersecting the first direction. The holder is disposed such that the brush is located between the holder and the second spring in the second direction. The holder holds the brush between the holder and the second spring.