Electric Motor Brush Holder Segmentation for Automated Assembly
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Solution Overview
Problem
Existing electric motor brush arrangements in mass production face challenges with fixed mounting and concentricity deviations due to the need for riveting metal cylinders on printed circuit boards, which is not suitable for automated processes.
Innovation Solution
The solution involves separate parts for holding brushes and fixing brush-springs, using disk- or plate-shaped elements with protrusions and recesses for easy assembly and manufacturing, including chamfered fittings for ball bearings and lead-throughs to accommodate brush springs and electronic components, allowing for flexible material choices and easier production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal cylinders are riveted on a printed circuit board to hold brushes, then the brushes can be securely mounted, but the manufacturing process becomes unsuitable for automated mass production
Solution Approach 1:
The invention divides the mounting structure into separate components: a printed circuit board for electronic connections and a separate brush holder component for mechanical brush support. This segmentation eliminates the need for riveting metal cylinders onto the PCB, as the brush holder is designed to be mounted using alternative methods suitable for automated production.
Solution Approach 2:
The invention replaces the mechanical riveting process with a different mounting mechanism that is compatible with automated production. The brush holder uses a design that allows for automated insertion and fixation, substituting the manual or semi-automatic riveting process with a more automated approach.
2Manufacturing precision
If brushes are fixedly mounted on a substrate, then positioning is precise, but concentricity deviations occur due to abrasion and mounting errors
Solution Approach 1:
The invention introduces a spring-loaded mechanism that allows the brush mounting to be dynamic rather than fixed. The spring compensation system automatically adjusts the brush position to maintain concentricity with the rotor, compensating for abrasion and mounting deviations while preserving initial positioning accuracy.
3Stability of the object's composition
If spring-loaded brush mounting is used to compensate for concentricity deviations, then concentricity is maintained, but the structure becomes more complex
Solution Approach 1:
The invention merges the spring compensation mechanism directly into the brush holder component, creating an integrated assembly rather than separate components. This integration reduces overall structural complexity while maintaining the concentricity compensation function, as the spring mechanism is built into the holder rather than being an add-on.
Data Source
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AI summary
The invention relates to an arrangement with fittings for at least two brushes for an electric motor, where to each fitting is assigned a bearing for carrying a brush-spring, where the arrangement includes two predominantly disk- or plate-shaped elements, the first disk- or plate-shaped element (BP) carrying the fittings for the brushes and the second disk- or plate-shaped element (ES) carries the bearings for carrying a brush-spring, and that the first disk- or plate-shaped element (BP) shows openings through which the bearings pass, and to an electric motor with such an arrangement.