IMPROVEMENTS IN OR RELATING TO ELECTRIC MOTORS AND COMPONENTS THEREFOR

Abstract: A support for the brushes of an electric motor comprises a member (39) of generally annular form in which is embedded an array of conductors. Parts (67,68) of the array are exposed at the inner and outer edges of the member (39). Brush boxes (79) have extensions (80) that clip over the exposed parts (67,68) of the array to secure the boxes (79) physically to the member (39) and to make electric connection with the array.

Description: This invention relates to electric motors and components therefor. The invention has particular reference to brush box mounting assemblies and to electric motors incorporating such assemblies. It has been proposed to employ a brush box mounting member of annular or part annular shape. The member is a printed circuit board and carries an exposed conductive array on one face thereof to which electrical connection is to be made from the brushes of the motor. The brushes are generally housed in brush boxes of an electrically conductive material, the boxes being mounted upon the board and electrical connection made thereto from the appropriate part of the array. It is an object of the present invention to enable the securing of the brush boxes to the ring and the electrical connection of the boxes to the appropriate parts of the array to be effectively and economically achieved. According to the present invention, a brush box mounting assembly for an electric motor comprises a member of generally annular form and comprising an array of electrical conductors embedded in a covering of an electrically insulating material, parts of the array being exposed through the covering, and brush boxes of electrically conductive material mounted upon the member in a manner such that each box is in direct contact with one or more of the parts to provide electrical connec­ tion thereto. The exposed parts of the array may lie adjacent edges of the member. The direct contact may be such that it also serves to secure the boxes to the member. Each brush box may have at least one extension that is engaged with an exposed part to make electrical connection therewith and to secure the box to the member. The or each extension may be an integral part of the box. The exposed parts may be arranged in pairs, one part of each pair lying on the inside edge of the member and the other part of the same pair lying on the outside edge of the member, and in which each box has one exten­ sion engaged with the one part and another extension engaged with the other part of a pair of exposed parts. The member may have location walls that locate the brush boxes on the member. The location walls may be integral with the covering. The location walls may be arranged in pairs in diametrically opposed positions on the member. The other part of each pair of exposed parts may be located between the walls of a pair of location walls. Preferably, the member is of true annular form, but it may, alternatively, be of gapped annular form, i.e. an incomplete annulus whose ends are separated by a gap. The generally annular member may also comprise an array, other parts of which are exposed to form fixed electric contact or contacts of a switch, the member also comprising a support surface and mounted upon the support surface for movement relatively thereto, a switch operating member for operating a movable contact or contacts of the switch. The support surface may comprise a curved wall upstanding from the generally-annular member and coaxial therewith. The switch operating member may seat round the wall. The generally annular member may include guide surfaces for the brush boxes, the wall being configured to allow passage through the wall of commutator brushes in the boxes. The switch operating member may be ring-shaped and be configured to allow passage therethrough of commutator brushes and to permit movement of the switch operating member for contact operating purposes. The switch operating member may carry the movable contact or contacts. A switch operating member carrying the movable contact or contacts may include an arm or arms extending therefrom which carry the movable contacts. The or each arm may include a recess in which a movable contact is located. The switch operating member may have two arms that extend radially from the switch operating member. Alternatively, the generally annular member may carry one or more pockets, the or at least some of the pockets accommodating the movable contact or movable contacts. The or each pocket may be formed, at least partially, by partitions extending from the generally annular member. The partitions may be formed integrally with the covering. The or each movable contact may be a part of a contact assembly comprising a body located in the pocket and movable therein by the switch operating member and carrying the movable contact. The movable contact may be resiliently mounted in the body. The body may be of generally tubular form in which case the movable contact comprises a contact bar extending radially from the body. The or each contact assembly may be movable by the cam surface on the switch operating member to move the movable contact into electrical contact with and away from the associated fixed contact or contacts. The or each contact assembly may include a rollable member located between the cam surface and the assembly. The generally annular member may be a complete annulus. The switch operating member may be linked to an actuator for actuating the switch operating member. Other parts of the array may extend from the material to form terminal connectors, part of the terminal connectors being sheathed by the material to form supports for brush springs of the brushes of the motor. The support may include brush springs each of which includes a portion mounted upon a sheathed part of a terminal connector. The support has, on or adjacent the sheathed part of each connector a rest or rests for supporting a brush spring on the part. The support may also comprise brush boxes mounted upon the member, brushes in the boxes, brush springs mounted upon the sheathed parts and stressed between a brush and a cooperating surface in a manner such as to urge the brush into a commutator engaging position. Each brush box may have an open-ended longitudinal slot through which the spring engages the brush. The cooperating surface may be part of a brush box. The invention also envisages an electric motor assembly including a support of any of the forms defined above. The electric motor assembly may include an armature mounted upon an armature shaft that extends through the generally annular member. One end of the armature shaft may be rotatably supported in a bearing assembly comprising a bearing mounted in the bore of a mounting sleeve having a plurality of spaced external, radially-extending fins. The fins may be of a reduced height over a part of their axial length as compared with the fin height over the remainder of the axial length. The junction between the parts of reduced height and the remainder of the fins may be adapted to form a seating surface for an annular mounting member by which the mounting sleeve is mounted. The mounting member may be of a resilient material. The bearing assembly may be mounted in an end housing of the motor assembly. The end housing may be apertured to receive the bearing assembly and is so contoured round the aperture as to provide a surface which locates and supports the mounting member. The bearing may be a bearing sleeve and the sleeve may be an interference fit in the bore. By way of example only, embodiments of the invention and an electric tool including the embodiments will now be described in greater detail with reference to the accompanying drawings of which:- Fig. 1 is a side view of the tool with a housing half removed, Fig. 2 is a side view of a motor assembly, on a different scale, Fig. 3 is an exploded view, on a different scale, of the motor assembly of Fig. 2, Fig. 4 is a plan view of a component of the motor assembly, Fig. 5 is a side view of the component of Fig. 4, Fig. 6 is a section on the line VI-VI of Fig. 4, Fig. 7 is a section on the line VII-VII of Fig. 4, Fig. 8 is a plan view, on a different scale of part of the component of Fig. 4, Fig. 9 is a section on the line IX--IX of Fig. 8, Fig. 10 is an underneath view of the component of Fig. 4, Fig. 11 is a perspective view from above and partly in exploded form of a brush ring and other components, Fig. 12 is a perspective view from below of the brush ring shown in Fig. 11, Fig. 13 is an explanatory diagram of an electrically conductive array, Fig. 14 is a plan view of a brush ring with some components removed, Fig. 16 is a vertical section of an end fitting and including some other components, Fig. 17 is a scrap view of a part of the end fitting, Fig. 18 is a an end view of a bearing assembly, Fig. 19 is a vertical cross section of the bearing assembly mounted on a wall, Figs. 20, 21 and 22 are diagrammatic representations of various circuit configurations, Fig. 23 is an explanatory diagram of another form of brush ring and electrically-conductive array, Fig. 24 is a plan view of the other form of brush ring with certain components mounted thereon, Fig. 24 is an underneath view of the brush ring of Fig. 24, Fig. 26 is a perspective view from above of the brush ring of Fig. 24, Fig. 27 is a vertical section of a switch assembly, Fig. 28 is a perspective view of the switch assembly with a component removed, Fig. 29 is a plan view on an enlarged scale of part of the brush ring of Fig. 24, Fig. 30 is a plan view of the brush ring of Fig. 24 showing certain components only, Fig. 31 is an explanatory diagram of a switch operating member and switch assemblies, Figs. 32 and 33 are, respectively, plan view and circuit diagram of a first circuit configuration incorporating the brush ring of Fig. 24, Figs. 34 and 35 are, respectively, plan view and circuit diagram of a second circuit configuration incorporating the brush ring of Fig. 24, Figs. 36 and 37 are, respectively, plan view and circuit diagram of a third circuit configuration incorporating the brush ring of Fig. 24, Figs. 38 and 39 are, respectively, plan view and circuit diagram of a further circuit configuration incorporating the brush ring of Fig. 24, and, Figs. 40 and 41 are, respectively, plan view and circuit diagram of a fifth circuit configuration incorporating the brush ring of Fig. 24. The appliance shown in Fig. 1 is a hand-held power drill. The drill has a casing of two-part clam-­ shell form, the clam-shells being made of a suitable plastics material. The drawing shows one half only of the casing, the other half being removed to reveal some of the working parts of the drill. In the half 1 is shown a motor unit 2 whose output shaft drives, via reduction gear 3, a chuck 4 mounted upon the output shaft 5 of the gearing 3. The casing is of "pistol" form with a handle 6 which is shown as accommodating a switch mechanism indicated at 7 and operable by a trigger 8 for control­ ling the application of power to the motor unit 2. The switch mechanism 7 is connected to a source of electric power via a drop-lead 9 held in a conventional cable clamp or labyrinth indicated at 10. As will be made clearer below, the switch mechanism may, alternatively, be housed elsewhere. The inside faces of the clam-shell halves are formed with location surfaces to locate the motor unit 2 and the gearing 3 and hold them securely in position but those surfaces are not shown in Fig. 1. The motor unit 2, shown by itself in Fig. 2 on a larger scale and in exploded form in Fig. 3 on a smaller scale, comprises a stator or field stack 11 of the conventional laminated form. The field stack 11 carries field windings, the projected parts of which are shown at 12 in Fig. 3. The projecting parts of the field coils are supported by end fittings 13, 14 of an electrically insulating material, for example a plastics material secured to the end faces of the field stack 11. End fitting 13 is shown in more detail in Figs. 4-10. It comprises a base 15 of generally annular form from one face of which extend four pins 16 integral with the base 15 and arranged in two pairs in diametri­ cally-opposed positions. Between the pins of each pair are holes 17 by which the ring is secured to the end of the field stack. From the other face of the ring in positions corres­ ponding approximately with those of the pins 16 are larger projections formed as sockets 18. The sockets are stepped internally as at 19 as can be seen in Fig. 9. Each socket also has an integral projecting tab 20. When seen in plan as in Figs. 4 and 8, the sockets are of rectangular shape. Located between the sockets 18 are supports 21 that extend inwardly from the base 15 and have arcuately curved portions 22 spaced over their extremities from the base and that conform to the shape of the internal pole pieces on the field stack. Seen in side view as in Fig. 5, each support is of truncated triangular form and carries, at its upper end, a finger 23 that extends outwardly from the support and is aligned with a partial gap 24 in the base 15. The sockets 18 house metallic terminals that engage the terminal connectors referred to below and to which the ends of the field coils are joined. The pins 16 are located in holes in the end face of the stack whilst the supports 21 retain the projecting ends 12 of the field windings in the conventional manner. The other end fitting 14 is identical with fitting 13 but does not have the sockets 18. Mounted for rotation in the field stack 11 is a rotor comprising an armature 25 (Fig. 3) supported on an armature shaft 26 having a commutator 27 at one end and a motor cooling fan 28 at the other. The cooling fan end of the shaft 26 is formed as a driving pinion 29 which meshes with input pinion 30 (Fig. 1) of the reduction gearing 3. The ends of the armature shaft 26 are supported in bearings in housings mounted upon the ends of the field stack 11. The commutator end of the shaft 26 is mounted in a plain bearing 30 forming part of a heat sink 31. The heat sink 31 is located in an aperture 32 in the end wall of a commutator end housing 33 and held in that aperture by a mounting ring 34 of a resilient material, for example rubber. Details of the end housing 33 and the heat sink 31 and its method of mounting will be given below. The commutator end housing 33 is a body of electrically insulating material and of generally tubular form with an annular portion 35 sized internally to fit over the end fitting 13 and the adjacent end of the field stack as can be seen in Fig. 2. Parts of the side wall of the housing 33 are cut away as at 36 to allow passage of cooling air. Two of the parts 36 in diametrically opposed positions have cut-away extensions 37 whose purpose will be described below. The housing 33 has an internal shoulder 38 against which seats a brush ring 39 when the motor unit is assembled. The fan end of shaft 26 is supported in a plain bearing 40 supported in an end wall 41 of a fan end housing 42. The housing 42 has an annular portion 43 which seats on the other end of the field stack 11 over end fitting 14. Portion 43 has two axially extending limbs 44 of arcuate form seen in end view, to the end faces of which the end wall 41 is secured by means of sector-shaped bosses 45 which locate in slots 46 in the limbs 44 and screws 47 that pass through screw holes in the end wall and screw into the bosses 45. A fibre washer 48 is located between the fan 28 and the end face of the plain bearing 40. The brush ring 39, further details of which are given below supports carbon commutator brushes 49 and has four terminal connectors 50 extending at right angles from one of its faces. Connectors 50 connect electrically with the metallic terminals in the sockets 18 during assembly of the motor unit 2 as will be described below. The brush ring 39 also has input connectors 51 extending at right angles from its other face. Connec­ tors 51 project through holes in the end wall of the housing 33 and enable electrical connection to be made to switch mechanism 7. The brush ring 39 also carries other components as will be made clear below. The brush ring 39 is a composite structure of generally annular form as can be seen from Figs. 11 and 12. The ring 39 is of an electrically-insulating material for example a plastics material incorporating an array of conductors that is encapsulated into the material during the moulding thereof. The array 52 shown hatched in Fig. 13 is formed from brass sheet, by stamping for example, and includes an external 'frame' 53 which serves to support the array during the moulding of the plastics material. The array comprises the input connectors 51 that extend at right angles to the plane of the array but which are also shown, for convenience, in Fig. 13 as lying in that plane. Plastics material is moulded round the array to encapsulate the greater part thereof. The terminal connectors 50 emerge from the edge of the ring 39 as shown in Figs. 11 and 12. After the brush ring 39 has been moulded, the frame 53 is removed by trimming off thereby leaving a basic circuit configuration that will be described below. Selected areas of the array are left exposed through the lower surfaces of the ring 39, such areas being indicated at 54. Further selected areas 55 of the array are also left exposed on both surfaces of the ring 39. Exposure of those surfaces is effected by the use of appropriately positioned cores during the moulding of the ring 39. Moulded integrally with the ring 39 round the central, circular aperture 56 therein is an upstanding wall 57 gapped at diametrically opposed positions 58. The upper edge of the wall 57 has two fingers 59 with bevelled upper edges 60. The fingers 59 are also located at diametrically opposed positions. As can be seen from Figs. 11 and 12, moulding material extends part-way up the input connectors 51 as indicated at 61 to form an electrically protective sheath around the connectors. That part of the sheath adjacent the surface of the brush ring is shaped to form spaced seating surfaces 62. Also moulded integrally with the ring 39 are spaced walls 63 that are aligned in a radial direction with the edges of the gaps 58 in the wall 57, and protective tubular extensions 64. The walls 63 extend, at their outer edges, to the periphery of the ring 39 and border recessed portions 65 of the edge of the brush ring that allow the connectors 50 to be turned from the plane of the array within the periphery of the ring. That edge also has other recesses 66 whose function is described below. The edge of the ring 39 is also cored out as at 67 on its upper surface (as seen in Fig. 12) to expose other areas of the array. The inner edge of the brush ring 39 is formed during moulding at areas 68 to expose other portions of the array and at other areas 69 intermediate areas 68. The wall 57 forms a bearing surface for a switch body 70 that is employed in certain embodiments of the invention as will be described below and which is held in place by the fingers 60. The switch body 70 shown in Fig. 11 has a central tubular portion 71 whose curved wall is cut-away as at 72 over circumferential distances somewhat greater than that of the gaps 58. The upper (as seen in Fig. 11) edge of the curved wall is also cut away as indicated at 73. Extending radially from the portion 71 and at diametrically opposed positions are bosses 74 each with a transverse passage 75 closed at its inner end. Each passage accommodates a metal ball 76 urged outwardly from the passage by means of a helical spring 77 housed in the passage. The metal balls 76 constitute moving switch contacts and they co-operate with exposed parts of the array, those exposed parts constituting the fixed contacts of the switch. Some of the fixed contacts are visible in Fig. 11 at 78. There are two sets of such fixed contacts disposed in diametrically opposed positions. One set co-operates with one of the metal balls 76 and the other set co-operates with the other of the metal balls. The switch body 70 is rotatable round the wall 57 within limits imposed by the brush boxes that extend through the gaps 58 in the wall 57. However, the actual movement of the body 70 is less and is indicated in Fig. 14, the two extreme positions of the body 70 being shown. Movement of the switch body 70 is effected by the user via a linkage connecting the body to an actuator which may be a member accessible through an aperture in the casing of the tool containing the motor, for example the drill shown in Fig. 1. Alternatively, the body 70 may be linked to the trigger 8 which, in this case, will be a multi-position trigger. The brush ring 39 supports two brush boxes 79. The brush boxes 79 are open-ended sheet brass pressings with axial mounting tags 80 which are crimped over the internal and external edges of the brush ring so making electrical connection with the exposed portions of the array in areas 67 and 68. As can be seen from Fig. 11, the walls 63 lie between the brush boxes 79 and the connectors 50 to provide a degree of electrical insulation and also to increase the tracking distance between those components. In addition to providing electrical connection for the brush boxes 79 to the array, the tags 80 also secure the boxes physically to the brush ring 39. Each brush box 79 has a slot 81 in its upper (as seen in Fig. 11) surface. The slots 81 permit engagement with the outer ends of brushes 49 of end portions 82 of brush springs. The brush springs include helical portions 83 mounted upon the sheathed parts of the connectors 51 and resting upon the seating surfaces 62. The other ends 84 of the brush springs are hooked to engage and be retained by lugs 85 pressed out of the side walls of the brush boxes. The sheaths 61 insulate the brush springs electrically from the connectors 51. The slots 81 are of a length sufficient to allow the spring end portions 82 to retain contact with the brushes and to keep the latter in engagement with the commutator despite brush wear. Figs. 14-17 show in more detail the way in which the brush ring 39 is accommodated within the commutator end housing 33, some components being omitted for the sake of clarity. Figs. 15 and 16 show the contour of the end wall 86 of the commutator end housing and the aperture 32 in which the heat sink 31 and bearing 30 are located. The aperture 32 is formed in an upstanding central boss 87 of the end wall 86, the inner side of the boss accommodating a part of the heat sink. Fig. 17 shows one of the holes through which extends the input connectors 51, the hole being indicated by reference numeral 88. The sheath 61 on the connector assists in the location of the connector centrally in the hole 88. Figs. 15 and 16 also show the encapsulation of the array in the plastics material of which the brush ring is formed, and the manner in which the tongues 80 of the brush boxes 79 make electrical contact with the array after having been crimped over the respective exposed parts thereof. Fig. 19 which is a scrap section through part of the end wall 86 shows form of and the manner in which the heat sink 31 is secured in the aperture 32. The heat sink 31 is a light allow casting of generally tubular form with an axial bore 31 a and spaced, radially extending fins 31 b along its external surface. As can be seen from Fig. 19, the depth of the fins 31 b is greater at one end of the heat sink, the junction between the parts of greater and smaller depth being rounded as to 31 e to form part of a location for an 'O' ring 31 c . The internal contour of that part of the boss 87 surrounding aperture 32 provides a rounded seat 31 d which forms the other part of a location for the 'O' ring 31 c . Located in the bore 31 a is the plain bearing 30 which is an interference fit in the bore. The spaced fins allow the circulation of air between them, such circulation being assisted, when the motor is in use by the action of the fan 28. The array 53 provides a network of conductors that may be modified to provide different electrical circuits each suitable for a particular set of controls with which the motor unit is to be provided. Fig. 20 shows, shaded, the basic circuit confi­ guration of the conductor network, the field coils 89 being indicated diagrammatically as joined to the connectors 50. By removing part 90 of the array, a simple series connected motor circuit is provided from the upper input terminal 51 then via the left-hand connector 50 to the left-hand field coil 89 and then via the lower brush 49, commutator 27 to the upper brush 49 and thence through the right-hand field coil 89 to the lower input terminal 51. Part 90 of the network is accessible for removal because it is one of the exposed parts 55 referred to above. In the simple case just described, the switch body 70 is not present and the switch contacts 78 are not part of the operative circuit. If the motor circuit just described is to include two RF chokes, parts 91 and 92 of the network are removed, such parts being left exposed during the moulding of the brush ring and are designated 55 over. Part 90 is also removed as before. Chokes 93 are connected in circuit by soldering them between the appropriate exposed parts 55 of the array. In Fig. 20, those parts are referenced 94, 95 for one choke and 96, 97 for the other choke. The choke leads are protected, at least partially, by the tubular extensions 64 of the brush ring 39 through which those leads pass. One of the chokes 93 is shown in Fig. 11 in its final position. A circuit including the chokes is completed from upper input 51 through left-hand field coil 89 to choke terminal 94, choke 93, choke terminal 95 to lower brush 49, commutator 27, upper brush 49, choke terminal 97, choke 93, other choke terminal 96, right-hand field coil 89 and back to the lower input terminal 51. Again, in this case, the switch body 70 is not present and the switch contact 78 are not part of the operative circuit. Fig. 21 is a view of the conductor array with speed control providing full speed and reduced speed. Speed reduction is provided by including a half-wave rectifier W1 in the circuit and using the switch body 78 to switch the rectifier W1 in and out of circuit in accordance with the motor speed required. As before, part 90 of the array is removed as are additional parts 88 and 105. This provides a circuit from upper input 51, through left-hand field coil 89 to fixed contact 102 of the switch, moving ball contact 76, to second fixed contact 101, lower brush 49, commutator 27, upper brush 49, fixed contact 100, moving ball contact 76, to second fixed contact 99, right-hand field winding 89 and lower input 51. The circuit just traced gives full speed. Reduced speed is obtained by rotating switch body 70 to switch in the rectifier W1 thereby completing a circuit from upper input 51, left-hand field coil 89, fixed contact 102, movable ball contact 76 to fixed contact 101, lower brush 49, commutator 27, upper brush 49, fixed contact 100, rectifier W1, movable ball contact 76, fixed contact 103, fixed contact 99, right-hand field coil 89 and lower input 51. Chokes can be fitted to the dual speed circuit just described by removing parts 91 and 92 as before and fitting the chokes in the positions described above. Reversal of the direction of rotation of the motor can also be obtained. The rectifier W1 is maintained to limit the motor speed in the reverse direction. The conductor array is shown in Fig. 22. As before, parts 88, 90 of the array are removed together with part 105. The forward direction of the motor is achieved via a circuit from upper input 51, left-hand field coil 89, fixed contact 102, movable ball contact 76, fixed contact 101, lower brush 49, commutator 27, upper brush 49, fixed contact 100, fixed contact 99, right hand field coil 89 to lower input 51. To reverse the direction of rotation, switch body 70 is rotated to a position providing a reverse direction circuit as follows:- upper input 51, left-hand field coil 89, fixed contact 102, movable ball contact 76, fixed contact 104, upper brush 49, commutator 27, lower brush 49, rectifier W1, contact 103, movable ball contact 76, fixed contact 99, right-hand field coil 89 to lower input 51. Again, if required, chokes can be added, in the manner described above, to the speed reversal circuit just described. Whilst the motor unit 2 can be assembled manually, it is preferred to assemble the components on an automated assembly line. However, in both cases, the assembly process is basically the same. The field stack 11 is made and assembled in a conventional manner as in the armature 25. A brush ring 39, complete except for brushes, is then offered up to the end ring 13 and connectors 50 firmly engaged in sockets 18. The commutator end bearing is put together by pressing the bearing 30 into the heat sink 31. The fan end bearing is put together in a generally similar fashion by pressing bearing 40 into the aperture in the end wall 41. The resilient ring 34 is mounted in a recess (described below) in the end wall of housing 35 after which the heat sink assembly comprising heat sink 31 and bearing 30 is pressed into the aperture in the end wall. Housing 35 is then located over the brush ring 39, the end fitting 13 and the adjacent end of the field stack 11. The periphery of the brush ring seats on the internal shoulder 38 referred to above. Housing 42 is next located over the end fitting 14 and the adjacent end of the field stack. Long field screws 104 are passed through axial holes in housing 43 and in the field stack and screwed into blocks 105 to hold the end housings 33 and 43 on to the field stack, the brush ring 39 being sandwiched between end fitting 13 and the internal shoulder 38. The blocks 105 are located in the extensions 37 of the cut-aways 36 in end housing 33. The next stage is to fit washers 48 and 106 and a spring washer 107 to the respective ends of the shaft 26 as shown in Fig. 3 and enter the armature 25 through the open end of housing 43 until the commutator end of the shaft engages in bearing 30. At this stage, a measurement is taken of the distance from the outer end face of one of the limbs 44 to the fan end housing location as identified by the adjacent end face of the stack 11. If the motor unit is being assembled manually, further washers are added to the fan end of the shaft 26 to bring the measured distance up to a specified value. In the case of automated assembly, the location of the bearing sleeve 40 in the end plate 41 is adjusted to provide a distance of the specified value and is then locked in position. In those ways, the degree of axial movement of the armature is confined to within an acceptable known value. End wall 41 is now secured to the limbs 44 of housing 43 using the two screw bosses 45 which locate in the recesses 46 in the limbs 44, the wall then being secured in place by screws 47 which screw into the bosses 45. Brushes 49 are now located in brush boxes 79 on the brush spring 39 and held in place by the brush springs. At this stage, the motor unit 2 can be tested both electrically and mechanically and if found to be satisfactory is then ready for inclusion in an appliance, for example, the hand drill of Fig. 1. Figs. 23-30 show another form of brush ring. Fig. 23 shows an array 120 with its external supporting frame 121 that serves to support the array during the moulding of the brush ring 122 which is of a plastics material as before and is shown in Fig .23 with the array 120 superimposed on it. The array 120 is generally similar to that described above having a terminal connectors 123 that connect to field windings via terminal connectors in the commutator end ring as before. It will be understood that the frame connection shown in Fig. 23 to the terminal connectors 123 will be trimmed off after the ring has been moulded. The position of the power input terminals 124 is different from those of input terminals 51 described above, the positions of terminals 124 are spaced further from the terminal connectors 123 than is the case in the construction described above, the extra spacing accommodating further connectors 125 whose function will be described below. To enable the physical form of the input connectors 124 and the further connectors 125 to be seen clearly, these connectors are shown additionally in the plane of the array 120. During moulding, the ring 122 is formed with "windows" that expose certain parts of the array. The windows which expose the parts shown cross hatched within the window through both the upper and lower faces of the ring are indicated at 126 in Fig. 23. Additional windows 127 are formed on the ring but these do not expose parts of the array and their function will be described below. In addition, further parts of the array indicated at 128 are left exposed on both faces of the ring 122. The upper surface of the ring 122 is also formed to expose those parts of the array shown cross hatched on Fig. 23. The undersurface of the ring is also formed to expose other parts of the array also shown cross hatched as indicated at 129 in Fig. 25. Those parts include areas 130 at the inner and outer peripheries of the ring 122 for the connection of brush boxes in a manner similar to that described above. During the moulding of the ring 122, integral supports 131 (Fig. 26) are provided for the brush spring 132, those supports having bases 133 on which the springs 132 rest. Sheathing 134 is also formed during moulding round the greater part of the terminals 124, 125 and the brush springs 132 could be mounted upon that sheathing if desired, instead of on the supports 131 which could then be dispensed with. Also formed integrally with ring 122 during the moulding thereof is the gapped wall 135, a series of partitions 136 that form pockets extending around the windows 126 and 127, long tubular columns 137 and walls 138 between the field connectors 123 and brush boxes 139, and short tubular extensions 140. The brush boxes 139 are secured physically to the brush ring 122 and electrically to the exposed portions by crimping over the exposed parts 130 of the array tongues 139 a that are integral with the boxes. Brushes, one of which is shown at 141, are urged into contact with the armature commutator by end 142 of the brush springs, the boxes 139 being slotted as at 143 to allow movement of the ends 142 along part of the length of the box as the brushes wear. The pockets 144-149 formed by the partitions 136 each accommodate switch contact assemblies shown in section in Fig. 27 and in perspective in Fig. 28. Each switch contact assembly comprises a cylin­ drical body 150 of a plastics material with an internal bore 151 that terminates at an internal transverse wall 152. The upper end of the body 150 has a peripheral wall 153 gapped at 90° intervals as indicated at 154. The upper face of the wall 152 is semi-spherical as indicated at 155 in Fig. 27, the curved contour extending up the inside of the wall 153. The side walls of the body 150 are slotted as at 156, 157 in diametrically opposed positions, the lower slots 157 lying on a diameter that is at right angles to that on which the upper slots 156 lie. As can be seen clearly in Fig. 27, the top and bottom length of the right-hand (as seen in Fig. 27) slot 156 is somewhat greater than that of the left-hand slot. Located in the upper slots 156 and guided for up and down movement thereby is a contact bar 158 whose ends project from the body 150 and have downwardly extending rounded contacts 159. The contact bar is of copper or some other material of low electrical resistivity. The upper face of the bar 158 has a central protuberance 160 that forms a lower seating for a helical spring 161 that locates between the seat 160 and the transverse wall 152, thus biassing the bar 158 into the position shown in Figs. 27 and 28 in which the bar is in contact with the lower edges of the slots 156. The spring 161 is entered through the larger right-hand slot of the slots 156 after the bar 158 has been positioned in the slots. Located in the lower slots 157 is pin 162 of a plastics material that also projects at both ends from the body 150. A second helical spring 163 of frusto-­ conical form is located between the bar 158 and the pin 162 biassing the latter into the position shown in Figs. 27 and 28 in which the pin is in contact with the lower edges of the slots 157. The space bounded by the wall 153 accommodates part of a roller 164 supported upon stub axles 165 that locate in diametrically opposed slots 154. The switch assemblies are positioned in the pockets by the lower ends of the bodies 150 that locate the windows 126, 127 in the brush ring, the pins 162 resting upon the upper face thereof. In the case of windows 126, the exposed parts of the array that bridge the windows are punched out leaving an unobstructed window with exposed portions of the array in diametrical opposed positions with respect to the window. Examples of the remaining exposed portions are referenced 166 (Fig. 26 and 27). Fig. 29 shows three of the pockets 144, 145 and 146 with spring assemblies located therein and it will be observed that in the case of the spring assemblies in pockets 144 and 145, the axles 145 of the rollers 164 are in the vertical same plane as that of the contact bar 158 but in the other spring assembly in pocket 146, the axles 165 lie in a vertical plane that is at right angles to that containing the associated contact bar 158. The provision of four slots 154 in the body 150 of the switch assembly enables the appropriate choice of two to be made in dependence upon the required orientation of the roller. The contact bars 158 of the various switch assemblies in the pockets 144, 145, 147 and 148 co-operate with exposed parts 166 of the array to carry out various switching operations connected with the operation of the motor. The assemblies in pockets 146 and 149 provide power supply switching as will be described below. A choice can be made during manufacture of the switching facilities that are to be provided and the array 122 will be modified accordingly and the necessary switch assemblies provided. When fitted, the assemblies are actuated by a cam plate 167 (Fig. 30) of annular form that is rotatably mounted over the wall 135 and rests upon the upper ends of the partitions 136. The plate 167 has a radially extending finger 168 by which the plate can be rotated into one or other of its various control positions. The finger extends outwardly beyond the outer periphery of the brush ring 122. The finger 168 is linked to an actuating member accessible to a user. The member may be accessible through an aperture in the casing of the tool for example the drill shown in Fig. 1. Alternatively, the finger 168 may be linked to the tool trigger which, in this case will be a multi-position trigger. The underneath (as viewed in Fig. 30) face of the cam plate 167 is formed with a circular cam track a part of which is shown at 169 in Fig. 31 and which is configured to provide actuation of the switch assemblies as required by the switching facilities to be provided. The track 169 has recessed portions 170 and when one of them is aligned with a switching assembly, the lower spring 163 allows the assembly to rise, the left-hand assembly seen in Fig. 31 being in that raised position. The cam plate 167 also has raised portions 171 which when aligned with a switch assembly contact the roller 164 and push down the assembly compressing both springs 161 and 163 and bring the rounded contacts 159 into electrical contact with the exposed parts 166 of the array. The use of the two springs 161 and 163 allows for manufacturing tolerances and avoids over stressing any components of the switch assembly. The array 120 provides a network of conductors that may be modified to provide different electrical circuits each suitable for a particular set of controls with which the motor unit is to be provided. Depending upon the particular set, a combination of switching assemblies is fitted although in a particular set no assemblies are fitted. By way of example, particular sets of controls will now be described with reference to Figs. 32-41. Fig. 32 shows the configuration of the array 120 for a basic motor circuit with a trigger controlled ON-OFF power switch in the handle of the tool containing the motor unit. There is no modification of the array and an electrical circuit is provided from the upper (Fig. 33) power input terminals 124 to connector 123 and thence to the left-hand field coil 172 and via connector 123 and the appropriate part of the array 120 to the lower brush 141, through the commutator to the upper brush 141. From the upper brush the appropriate parts of the array 122 connect with a connector 123 to the right-hand field winding and thence back to the lower input terminal 124. No switch assemblies are used and the motor unit has a single speed only. Fig. 34 shows the configuration of the array 120 for a motor unit in which a single pole power supply switch is mounted upon the brush ring 122 and replaces the trigger operated handle switch referred to in the immediately preceding example. To permit connection of the switch, that part 173 of the array 120 lying across the lower right-hand (Figs. 23 and 34) window 126 is removed and a switch assembly is located in the associated pocket 146. The contact bar 158 of the switch assembly is shown schematically in Fig. 35 and it controls the connection of the lower input connector 124 to the adjacent terminal 123. A cam plate 167 is seated over the wall 135 and secured in place against the upper surfaces of the partitions 136 by the end moulding within which the brush ring is located. The circuit of the example shown in Figs. 34 and 35 is identical with that described above with reference to Figs. 32 and 33 except that to energise the motor the user has to rotate the cam ring 167 using the finger 168 from position POS1 to position POS2 to depress the switch assembly to bring the contact bar thereof into electrical contact with the related exposed parts 166 of the array. Rotation of the cam ring 167 in the opposite direction switches the motor unit off. If desired, a double pole power switch may be provided by punching out part 174 of the array (Figs. 23 and 34) and fitting a switch assembly in the associated pocket. The array 120 can be adapted to provide a degree of control of the speed of the motor by connecting a diode in circuit and by including a switch assembly to short out the diode to give full motor speed. Fig. 36 shows an array 120 adapted to receive a diode 175 that is connected across parts of the array connection of the latter being effected to parts 176 that are exposed on the underneath surface of the brush ring 122. The diode leads are protected by the short tubular extensions 140 referred to above. Short circuiting of the diode 175, when required, is effected by the inclusion of a switching assembly in the pocket 177 (Fig. 36), the contact bar of the assembly being shown at 178 (Fig. 37). The example shown in Figs. 36 and 37 also includes a single pole switch controlling power input to the motor unit. This is identical with the single pole switch described above with reference to Figs. 34 and 35. Rotation of cam ring 167 from position POS 1 to position POS2 energises the motor unit at reduced speed, the diode 175 then being in circuit. Movement of cam ring 167 to position POS3 short circuits the diode and this allows the motor to run at full speed. A further set of controls is shown in Figs. 38 and 39. Control of power supply is effected by a trigger controlled switch on the handle of the tool containing the motor unit so that no power control switches are mounted upon the brush ring. The control includes a reversing ability and a speed control unit shown in Fig. 39 by block 179. The unit is connected in power supply leads to terminals 124 and is housed in the casing of the tool. The unit is user controlled and enables one or other of several different motor speeds to be selected. The circuit of Fig. 39 also includes suppression chokes 180, 181 that are connected to the array 120 at points 182, 183 (Fig. 25) using parts 129 of the array exposed on the undersurface of the brush ring. To bring the chokes into circuit, it is also necessary to remove parts 184 (Fig. 25) of the array that are exposed through windows 128. Reversal of the direction of rotation of the motor is provided by switching assemblies located in pockets 185, 186, 187 and 188 (Fig. 38) and by adding a connecting link 189 across connecting points 190 (Figs. 23 and 24) of the array. Such connecting points are accessible through the upper face of the brush ring and short tubular shields similar to shields 140 but not visible in Fig. 26. As before, position POS2 of the cam ring 167 is the "OFF" position of the motor unit. Movement of the cam ring 167 to position POS1 applies power to the unit and allows rotation of the motor in a forward direction via a circuit from the speed control unit 179 to left-hand upper connector 123, left-hand field coil 172, lower left connector 123, choke 180, closed switch assembly in pocket 186, lower brush 141, commutator, upper brush 141, closed switch assembly in pocket 187, choke 181, upper right connector 123, right-hand field coil 172, back to the speed control unit 179. Movement of the cam ring 167 to position POS3 reverses the direction of rotation of the motor by opening the switch assembly in pocket 186, closing that in pocket 185, opening that in pocket 187 and closing that in pocket 188. Those changes provide a circuit from the speed control unit to the upper left connector 123, left-hand field coil 172, closed switch assembly in pocket 185, upper brush 141, commutator, lower brush 141, closed switch assembly in pocket 188, choke 181, right-hand field coil 172 and back to the speed control unit. A further variation on the possible motor unit control is shown in Figs. 40 and 41. The variation includes reversal of rotation, chokes 180, 181, diode 191 effective in the reverse direction of rotation of the motor unit, and a double pole power input switch. The rotational speed of the motor in the reverse direction of rotation is restricted by the diode which is connected across points 190 (Fig. 23). In the forward direction of the motor, ,the control circuit is energised when the cam ring 167 is moved from its "OFF" position - POS2 - to position 1. The circuit can be traced from upper input terminal 124, closed input switch 158, upper left connector 123, left-hand field coil 172, lower left-hand connector 123, choke 180, closed switch assembly in pocket 186, lower brush 141, commutator, upper brush 141, closed switch assembly in pocket 187, choke 181, right-hand field coil 172 and via closed input switch 158 to right-hand input terminal 124. Movement of the cam ring to position POS3, closes the switch assembly in pocket 185 and opens that in pocket 186, closes switch assembly in pocket 188 and opens that in pocket 187. That action brings diode 191 into circuit and reverses the direction of rotation of the motor unit. The circuit can be traced from upper input terminal 124, closed input switch 158, left-hand field coil 172, lower left-hand connector 123, choke 180, closed switch assembly in pocket 185, upper brush 141, commutator, lower brush 141, diode 191, closed switch assembly in pocket 187, choke 181, right-hand field coil 172, lower right-hand connector 123, closed input switch 158 and right-hand input terminal 124. Other combinations of the various circuit components are possible as will be evident to those skilled in the art. Although it is assumed in the description of the brush ring shown in Fig. 26 that power connections are made to input terminal 24 by means of space terminals, and terminals have apertures 195 to enable screw type terminations to be fixed to the connectors.

Claims: 1. A brush box mounting assembly for an electric motor comprising a member of generally annular form supporting an array of electrical conductors and brush boxes mounted upon the member characterised in that the array is embedded in a covering of an electrically insulating material, and in that parts of the array are exposed through the covering to enable electrical connection to be made to the brush boxes. 2. An assembly as claimed in claim 1 characterised in that the exposed parts lie on the periphery of the member. 3. An assembly as claimed in claim 1 or 2 characterised in that the member has an inside edge and an outside edge, the exposed parts being arranged in pairs, one part of each pair being located on one edge and the other part of the pair being located on the other edge. 4. An assembly as claimed in claim 3 characterised in that each brush box has axial connecting tags that are formed round the parts of a pair of parts to secure the brush box to the board and to make electrical connection between the box and the parts of the pair of parts. 5. An assembly as claimed in any one of claims 1-5 characterised in that the member carries a support on which is mounted a switch operating member, in that other parts of the array are exposed to form fixed electrical contacts for co-operation with movable electric contacts operable by the switch operating member. 6. An assembly as claimed in claim 5 characterised in that the support comprises a curved wall upstanding from the member. 7. An assembly as claimed in claim 6 characterised in that the switch operating member locates on the wall and is guided for movement thereby. 8. An assembly as claimed in any one of claims 5-7 characterised in that the member carries pockets in which the movable contacts are located. 9. An assembly as claimed in claim 8 characterised in that each movable contact comprises a body movable in the pocket by the switch operating member and carrying the movable contacts. 10. An assembly as claimed in claim 9 characterised in that the movable contacts comprises a contact bar carried by the movable body. 11. An assembly as claimed in claim 10 characterised in that the switch operating member includes a cam surface for moving each movable body via a rollable member interposed between the cam surface and the body. 12. An assembly as claimed in any one of the preceding claims characterised in that the annular member has posts for carrying brush springs for urging brushes in the brush boxes towards a commutator. 13. An electric motor including a stator on which is mounted a brush box mounting assembly as claimed in any one of the preceding claims and a rotor with a commutator encircled by the mounting assembly characterised in that the rotor is rotatably mounted in bearing means at each end thereof characterised in that one of the bearing means comprises a bearing assembly including a mounting sleeve having a bore, a plurality of spaced external, outwardly extending fins, and a bearing mounted in the bore. 14. An electric motor as claimed in claim 13 characterised in that the fins are of a reduced height over part of their axial length as compared with the fin height over the remainder of the axial length. 15. An electric motor as claimed in claim 14 characterised in that the junction between the fins of reduced height and the remainder of the fins forms a seating surface for an annular mounting member of a resilient material.

Inventors: SANDERS, ANTHONY JONATHAN
Applicants: BLACK & DECKER INC.
Application year: 1986
Main classification: H02K5
IPC codes: H02K5, F16C37, F16C27, H02K11, H02K23