Brushless Commutator Equalizing Units for Motor Reliability
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Solution Overview
Problem
Brush motors face a high risk of fusing equalizing wires due to excessive current flow, which is not adequately addressed by existing designs that rely on fewer brushes and longer equalizing wires.
Innovation Solution
The design incorporates a rotor with a commutator and equalizing units formed by twisted pairs of equalizing wires that connect equipotential segments in closed loops, reducing current density and heat production in each wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the number of brushes is reduced and equalizing wires are used to connect equipotential segments, then the device complexity is reduced, but the current density in equalizing wires increases causing high risk of fusing
Solution Approach 1:
The patent divides the single equalizing wire connection into multiple parallel equalizing wires. Instead of using one wire to connect equipotential segments, multiple wires are used in parallel, thereby segmenting the current path and reducing current density in each individual wire, which reduces the risk of fusing while maintaining the reduced brush configuration.
Solution Approach 2:
The patent introduces additional equalizing wires as intermediary elements to distribute the current flow. These intermediary wires act as mediators between the equipotential segments, providing multiple pathways for current flow and reducing the burden on any single wire, thus preventing fusion while maintaining device simplicity.
2Device complexity
If equalizing wires are used to replace brush pairs, then the number of brushes can be reduced, but the length of equalizing wires increases leading to higher resistance and heat generation
Solution Approach 1:
The patent segments the current path by introducing multiple parallel equalizing wires. This segmentation reduces the effective resistance of the equalizing connection system and distributes heat generation across multiple wires, preventing excessive temperature rise in any single wire even when replacing brush pairs.
Solution Approach 2:
The patent combines multiple equalizing wires in parallel to create a composite connection system. By merging multiple wire paths, the overall resistance is reduced and heat generation is distributed, allowing the system to replace brushes with equalizing wires without suffering from excessive heat in individual wires.
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 significantly reduces the risk of fusing equalizing wires by distributing current more evenly and reducing heat generation, while also potentially using fewer brushes and less material.
Implementation Method 1
a plurality of equalizing units, each of the equalizing units electrically connecting together a respective plurality of equipotential segments, wherein the equalizing units form a plurality of parallel electric circuits between the segments of the respective plurality of equipotential segments
Implementation Method 2
equalizing units formed by twisted pairs of equalizing wires
Data Source
AI summary
An electric motor includes a stator, a rotor, and multiple brushes. The stator forms multiple poles. The number of brushes is less than the number of stator poles. The rotor includes a commutator, windings, and equalizing units. The commutator includes segments electrically connected with the windings. Each of the equalizing units is electrically connected with multiple equipotential segments to make the equipotential segments have the same potential. Multiple parallel circuits are formed between the equipotential segments by the equalizing unit. The brushes are arranged to slidably contact the segments of the commutator.