Modular Contact Assembly for Rotating Machine Tool Brush Replacement
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Solution Overview
Problem
The existing ultrasonic machine tools require a time-consuming, complex, and labor-intensive process to replace worn brushes, which results in significant downtime and maintenance costs due to the need for extensive disassembly and reassembly.
Innovation Solution
A modular contact assembly that allows for quick and reliable removal and replacement of worn brushes, featuring a mounting plate with actuated conductive brushes and energy supply connections, enabling a simple 'plug-in' mechanism for swapping out worn assemblies with new ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the traditional brush replacement procedure is used, then the brushes can be replaced, but the process is time-consuming (over an hour) and requires extensive disassembly and reassembly
Solution Approach 1:
The contact assembly is divided into modular components: a removable mounting plate containing the brushes, electrical contacts, and actuator, which can be detached as a single unit from the housing. This segmentation allows the brushes to be replaced by simply removing and reinstalling the entire mounting plate assembly, reducing replacement time from over an hour to just a few minutes while maintaining all necessary electrical and mechanical connections.
Solution Approach 2:
The mounting plate is pre-assembled with all necessary components (brushes, electrical contacts, actuator, and connections) before installation. This preliminary assembly ensures that all parts are properly positioned and connected prior to installation, eliminating the need for complex on-site assembly and reducing the risk of misfitting or losing small parts during replacement.
2Ease of repair
If the traditional brush replacement procedure is used, then the brushes can be replaced, but the process is complex and labor-intensive requiring disconnection of electrical wiring and removal of various fasteners
Solution Approach 1:
Multiple components (brushes, electrical contacts, actuator, and their connections) are merged into a single integrated mounting plate assembly. This consolidation means that all these elements are moved, installed, and connected as one unit, dramatically simplifying the replacement procedure from a complex multi-step process involving numerous fasteners and wiring disconnections to a simple plug-in operation.
Solution Approach 2:
The mounting plate serves multiple functions simultaneously: it holds the brushes, provides electrical contacts, houses the actuator mechanism, and maintains all necessary connections. This multi-functionality in a single component reduces the number of separate parts and assembly steps required, making the replacement procedure less complex and more universally applicable.
3Ease of repair
If the traditional brush replacement procedure is used, then the brushes can be replaced, but there are risks of misfitting or losing small parts
Solution Approach 1:
By segmenting the contact assembly into a self-contained mounting plate module, all small parts (fasteners, electrical connections, actuator components) are retained within the modular unit. This eliminates the risk of losing small parts during replacement, as the entire assembly is handled as one piece that is simply removed and reinstalled without disassembly.
Solution Approach 2:
All connections and component positions are predetermined and pre-assembled on the mounting plate before installation. This preliminary configuration ensures proper fitting and alignment when the assembly is installed, eliminating the risk of misfitting parts that could occur during manual assembly of individual components.
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 solution significantly reduces the brush change-out time from over an hour to just a few minutes, enhances reliability, and eliminates risks associated with misfitting or losing small parts, transforming the brush change procedure into a 'plug and play' operation.
Implementation Method 1
a piezoelectric transducer that is connected to an electrical power supply. The power supply causes the piezo transducer to oscillate axially and radially along the spindle axis.
Implementation Method 2
a pair of electrically conductive brushes is used. The brushes are connected to an alternating voltage supply contained in a stationary housing of the mill, and the brushes are in contact with respective rotating terminal surfaces of a slip ring power coupling
Data Source
AI summary
A modular contact assembly for transferring electrical energy from a fixed object to a rotating object, and a machine tool that includes the contact assembly. The machine tool may include a housing, a rotating spindle mounted in the housing, and an electrical device mounted in the rotating spindle. The contact assembly includes a mounting plate joinable to a housing by movement of the plate into an attached position on the housing; a first brush assembly, first and second electrical contacts disposed in the mounting plate, an actuator joined to the mounting plate, and a first energy supply connection disposed in the mounting plate and in communication with the actuator. The machine tool may also include a magnet that is rotatable a quarter turn to retain the contact assembly in the machine tool. The electrical device may be an ultrasonic transducer operable to perform ultrasonic machining by the tool.