Rotary Table Brush Module With Dual Push Units for Stable Contact
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Solution Overview
Problem
Existing rotary table brush modules experience significant vibration, shaking, slipping, and line contact during high-speed rotation, leading to damage of the peripheral surface and poor conduction due to inadequate design, particularly in electrical discharge machining applications.
Innovation Solution
A brush module design featuring dual opposing pushing units with elastic elements and guiding grooves that provide balanced forces to resist lateral thrust and ensure stable contact, combined with automatic return mechanisms to prevent tilting and excessive friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single elastic damping assembly is used to press against the carbon brush, then the brush is pushed towards the opening, but excessive friction occurs between the carbon brush and the carbon brush box, causing damage or jamming
Solution Approach 1:
The single elastic damping assembly is divided into two separate pushing units: a first pushing unit with a first elastic element and a first pushing member, and a second pushing unit with a second elastic element and a second pushing member. Each unit independently presses against opposite sides of the brush, distributing the friction load and preventing excessive friction between the brush and housing.
Solution Approach 2:
Different elastic elements are configured with different properties tailored to specific directional requirements. The first elastic element has a first elastic coefficient and the second elastic element has a second elastic coefficient, allowing each side of the brush to be pushed with appropriately differentiated forces based on local friction conditions.
2Reliability
If the brush is pushed strongly towards the opening to maintain contact, then electrical conduction is improved, but vibration, shaking, and slipping increase during high-speed rotation
Solution Approach 1:
The first and second pushing units generate opposing pushing forces that act as counterbalancing forces against the lateral thrust generated by friction during high-speed rotation. This counteraction reduces vibration, shaking, and slipping while maintaining stable electrical contact between the brush and rotary disk.
Solution Approach 2:
The elastic elements are pre-compressed to generate preliminary pushing forces before rotation begins. This preliminary action ensures the brush is already positioned correctly and maintains contact stability from the start of rotation, preventing vibration and slipping during high-speed operation.
3Adaptability or versatility
If the brush is allowed to tilt during rotation, then it can adapt to surface variations, but excessive friction occurs between the brush and rotary disk, potentially burning out the motor
Solution Approach 1:
The first and second pushing units apply preliminary counteracting forces to prevent brush tilting before it occurs during rotation. By opposing the lateral thrust that would cause tilting, the system maintains the brush in a stable, non-tilted position, preventing excessive friction and potential motor burnout while still allowing necessary contact adaptation.
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
The design significantly reduces vibration, shaking, and slipping, maintains stable electrical contact, and prevents damage to the rotary disk, while allowing for automatic brush return and energy savings.
Implementation Method 1
the elastic member is sleeved on the conductive wire and pressed between the bottom surface and the end face to provide a force for pushing the brush towards the opening
Implementation Method 2
to resist the lateral thrust generated by friction between the brush and the rotary disk of the rotary table
Implementation Method 3
a first elastic element and a first pushing member, wherein the first pushing member presses against the first side of the brush and provides a first pushing force
Data Source
AI summary
A brush module for a rotary table includes: a housing, a brush unit, a first pushing unit and a second pushing unit, the brush unit includes a brush disposed in the housing, a conductive wire electrically connected to the brush, and a pushing force for pushing the brush towards the opening of the housing. The first and second pushing units oppositely provided on the housing provide the brush a first and a second pushing forces in opposite directions to resist the lateral thrust generated by friction between the brush and the rotary disk of the rotary table, thereby greatly reducing the vibration, shaking, slipping, line contact and other conditions of the brush caused by high-speed rotation of the rotary disk, avoiding damaging the peripheral surface of the rotary disk, and maintaining good electrical contact between the brush and the rotary disk.