Motor Brush Quick Change Assembly Design
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Solution Overview
Problem
The existing motor brush assemblies require disconnecting and reconnecting electrical leads during replacement, leading to increased downtime, inefficiency, and the need for trained technicians, especially in automated production facilities, as the brushes wear out and need to be replaced.
Innovation Solution
A motor brush quick change assembly featuring flexible electrical spring contacts and brush units with a carrier, conductive housing, and a biasing member that allows for direct electrical connection and mechanical attachment, enabling quick removal and replacement without separate electrical leads, facilitating robotic operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional motor brush assemblies with separate electrical leads are used, then electrical connection can be maintained, but replacement time increases and automation becomes difficult
Solution Approach 1:
The patent combines the electrical lead function and brush holder function into a single integrated assembly. The spring contacts are built into the brush assembly itself, eliminating the need for separate electrical leads that require disconnection and reconnection during replacement. This merging of functions directly reduces replacement time while maintaining electrical connectivity throughout the process.
Solution Approach 2:
The brush assembly is designed as a multi-functional unit that simultaneously provides mechanical support, electrical connection, and spring pressure application. The spring contacts serve multiple purposes: maintaining electrical connection, applying pressure to the commutator, and enabling quick attachment/detachment. This multi-functionality reduces the number of separate components needed during replacement operations.
2Productivity
If traditional brush replacement procedures are used, then trained technicians are required, but productivity decreases
Solution Approach 1:
The patent divides the motor brush system into separable modular units - the brush assembly can be independently removed and replaced without affecting other motor components. This segmentation allows for tool-free, quick-change replacement that does not require disassembling the entire motor or specialized technical knowledge, thereby improving productivity while maintaining ease of operation.
Solution Approach 2:
The spring-loaded brush assembly is designed to be self-retaining and self-releasing. The spring pressure automatically maintains electrical contact during operation and facilitates easy detachment during replacement without requiring external tools or complex manipulation procedures. This self-service design enables untrained operators to perform replacements quickly, boosting productivity.
3Reliability
If electrical leads are disconnected for brush replacement, then brush can be replaced, but electrical connection is interrupted
Solution Approach 1:
The spring contacts are pre-installed and pre-positioned within the brush assembly housing before the brush is installed. This preliminary preparation ensures that electrical connection is established immediately upon brush installation without requiring separate lead connection steps. The design maintains continuous electrical availability throughout the replacement process, enhancing reliability while simplifying the manufacturing assembly sequence.
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 reduces downtime and operational costs by allowing for rapid and efficient replacement of motor brushes, enabling robotic handling and maintaining continuous electrical connection during the process.
Implementation Method 1
a plurality of flexible electrical spring contacts with each of the electrical spring contacts comprising an elongated shape
Implementation Method 2
an electrically conductive housing mounted to the carrier with the housing comprising a receptacle and a contact surface, and a brush mounted in the receptacle and with a first end extending outward from the receptacle away from the carrier with the brush contacting against and being electrically connected to the contact surface
Data Source
AI summary
A motor brush quick change assembly that includes brush units and electrical spring contacts. The brush units include a carrier with a housing and a brush. The electrical spring contacts are connected to an electrical device. Each of the brush units is configured to be removably attached to the electrical device to contact one of the electrical spring contacts. The brush unit thus provide for both a mechanical and electrical connection to the electrical device. The brush units are configured to prevent the need for separate electrical leads that require separate attachment and detachment to the electrical device. This design provides for straight-forward removal and replacement that can be performed by a robotic device or an operator.