Tilted Brush Electric Motor Assembly
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Solution Overview
Problem
Existing electric motor designs require complex and time-consuming assembly processes due to the need to invert the yoke housing and brush holder, while also lengthening the axial length of the yoke housing when the brush holder is not fully received within it.
Innovation Solution
The electric motor design features a yoke housing with an opening at one axial end, where a brush holder is installed, guiding brushes that are tilted relative to the rotational axis, allowing them to be slidably contacted with the commutator, and the brush holder is clamped between the yoke housing and gear housing, minimizing the axial length and maintaining a low profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the brush holder is entirely received in the yoke housing, then the brushes can be installed from the yoke housing side without inverting the assembly, but the axial length of the yoke housing is lengthened
Solution Approach 1:
The brush holder is positioned to extend in the radial direction beyond the yoke housing rather than being entirely contained within it axially. This dimensional repositioning allows brush installation from the yoke housing side while avoiding axial length increase of the housing.
Solution Approach 2:
The brush holder is divided into a first portion received by the yoke housing and a second portion extending radially outward. This segmentation allows different portions to serve different functions: the first portion provides stable mounting and brush access from the yoke housing side, while the second portion enables radial extension without increasing axial length.
2Length of stationary object
If the brush holder is installed outside the yoke housing, then the axial length of the yoke housing is reduced, but the assembly must be inverted for brush installation
Solution Approach 1:
Instead of positioning the brush holder entirely outside the yoke housing (which would reduce axial length but complicate assembly), the design extends the brush holder radially outward from the yoke housing. This allows the assembly to remain in its original orientation during brush installation while maintaining a compact axial profile.
3Length of stationary object
If the brushes are tilted relative to the perpendicular plane, then the slide contact surface can be disposed axially outside the opening, but the brush holder structure becomes more complex
Solution Approach 1:
The brushes are tilted at an angle relative to the plane perpendicular to the rotational axis, creating an asymmetric configuration. This asymmetry allows the slide contact surface to extend axially outside the opening, enabling compact housing design while the tilted orientation naturally guides brush movement along the commutator surface.
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 design simplifies the assembly process by allowing brush installation without inverting the assembly and reduces the axial length of the yoke housing, maintaining a compact profile and minimizing brush abrasion dust dispersion.
Implementation Method 1
brushes that slidably contact a commutator
Data Source
AI summary
Each of a plurality of brushes is tilted relative to an imaginary plane that is perpendicular to a rotational axis of an armature and is placed on one axial side of a brush holder, at which an interior of a yoke housing is located. A radial inner end part of each brush has a slide contact surface, which is generally parallel to the rotational axis of the armature and slidably contacts an outer peripheral surface of a commutator. At least a portion of the slide contact surface of each brush is axially disposed outside of an opening of the yoke housing.