EP1801938B1 - Brush for a sliding-track or commutator system of an electrical machine with a monitoring apparatus for wear of the brush and a method for monitoring the wear of a brush - Google Patents

Brush for a sliding-track or commutator system of an electrical machine with a monitoring apparatus for wear of the brush and a method for monitoring the wear of a brush Download PDF

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Publication number
EP1801938B1
EP1801938B1 EP06125064.3A EP06125064A EP1801938B1 EP 1801938 B1 EP1801938 B1 EP 1801938B1 EP 06125064 A EP06125064 A EP 06125064A EP 1801938 B1 EP1801938 B1 EP 1801938B1
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EP
European Patent Office
Prior art keywords
brush
impedance
wear
sensor
signal
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EP06125064.3A
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German (de)
French (fr)
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EP1801938A2 (en
EP1801938A3 (en
Inventor
Anton Paweletz
Robert Schenk
Gunter Meyer
Thomas Peuser
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SEG Automotive Germany GmbH
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SEG Automotive Germany GmbH
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00—Rotary current collectors, distributors or interrupters
    • H01R39/02—Details for dynamo electric machines
    • H01R39/58—Means structurally associated with the current collector for indicating condition thereof, e.g. for indicating brush wear

Definitions

  • the invention relates to an arrangement for monitoring the wear of a brush of the slideway or commutator of an electric machine, as for example from the DE 10257623 A1 has become known.
  • This document shows a diagnostic device for determining the length of slip ring brushes in Schleifbahnan effet füren, or collectors of electrical machines.
  • an inductive sensor is provided for determining the brush length, which is connected to an evaluation unit for evaluating the sensor signals for determining a value corresponding to the brush length.
  • the inductive sensor has one or more coils which comprise the brush as a whole.
  • the monitoring unit also in the form of an inductive displacement sensor, arranged in a separate, bolted to the brush holder housing.
  • a core of the inductive displacement sensor is coupled via a pin-shaped extension and via a further coaxial with the brush arranged connecting element with the brush and along with this longitudinally displaceable.
  • the publication SU 729 708 A1 describes a monitoring device for the wear of a slidably mounted in a brush holder brush an electric machine. In this case, a magnetic measuring section is integrated in a brush body of the brush.
  • the publications SU 756 529 A1 and SU 860 187 A2 describe similar monitoring devices.
  • the document US 4,344,072 A relates to a monitoring device for a wear of a brush of an electric machine.
  • the monitoring device has a first brush which contacts a commutator.
  • a second brush is arranged in the first brush, wherein the second brush is electrically insulated from the first brush by means of an insulating layer
  • the invention has for its object to provide an apparatus and a method for monitoring the wear of a brush of an electric machine, which operate reliable, can be produced at low cost and require little or no additional space in the machine, so that they are in conventional Brush systems can be integrated or exchanged for them. This is achieved by the characterizing features of the parent device and method claims.
  • the base substance of the brush has a significantly different, preferably lower electrical conductivity ⁇ I than the measuring section integrated in the brush.
  • the base substance of the brush consists of an unfilled or of a metal-filled carbon material with an electrical conductivity ⁇ I in the range between about 0.05 and 20 MS / m, while the use in the brush for clear demarcation of the impedance Z measured from the sensor made of metal , preferably made of copper with an electrical conductivity ⁇ 2 of 56 to 57 MS / m.
  • the measuring principle can also be reversed by using a dielectric as the material that is fairly integrated into the brush with a different electrical conductivity ⁇ 2 than the base substance of the brush, so that the impedance Z drops significantly in this measuring range the permissible wear area of the brush.
  • the integrated into the brush section with different electrical conductivity with respect to the ground substance of the brush is electrically insulated and not flowed through by the working current of the brush to prevent the influence of the operating current on the impedance measurement.
  • the connection between the mission and the brush can also be made by gluing, so that with regard to the design of the parts to be joined no or almost no additional effort.
  • a positive connection can be additionally secured by an adhesive connection.
  • a riveted connection between the brush and the insert is advantageous.
  • the impedance sensor is structurally separated from the evaluation unit and integrated as a compact unit directly into the brush holder.
  • the evaluation unit advantageously a signal generator for the supply of the sensor with an AC voltage U can be integrated.
  • Such an arrangement is structurally very variable and can be easily installed without significant additional space in the brush area of the machine.
  • the inventive method for monitoring the wear of a brush of the slideway or Kommutatorsystems an electrical machine is characterized in that a fixedly arranged impedance sensor with an AC voltage U or a signal sequence in the frequency range of 100 kHz to 30 MHz, preferably in a range of 500 kHz is fed to 3MHz.
  • the sensor supplies therefrom a variable impedance signal as a measure of the remaining brush length to an evaluation unit.
  • This method is very reliable with little additional effort and ensures an easily detectable by simple means measuring signal for the wear of the brush, so that conventional difficulties are avoided by an unforeseen brush failure.
  • the brush is turned off by the output of the evaluation of the power supply, as soon as a predetermined signal level is exceeded. This ensures that consequential damage is safely avoided in critical applications.
  • FIG. 1 is denoted by 10 a slip ring or commutator of an electric machine, not shown, which is connected via a brush 12 and a wire 13 to the positive terminal 14 of a DC voltage network.
  • the brush 12 is held longitudinally displaceable in a brush holder 18 to the commutator or slip ring 10 and is pressed by a spring 20 which is centered on an extension 22 of the brush 12 to the slip ring or commutator 10.
  • the negative terminal 16 of the DC voltage network is connected to a further, only schematically drawn brush, which is designed and maintained similar.
  • the monitoring device for the wear of the brush 12 has a contactless sensor device in the form of an impedance sensor 24 with a coil 26 and an E-shaped magnetic core 28, which is arranged directly adjacent to the brush 12 adjacent and the brush has no closed magnetic circuit.
  • the impedance sensor 24 is connected to an evaluation unit 30, which includes an impedance measuring device 32 and a signal generator 34 for feeding the coil 26 with a high-frequency voltage U.
  • the immediately adjacent to the impedance sensor 24, in the brush holder 18 longitudinally guided brush 12 is designed as a two-component component. It consists essentially of an unfilled or partially metal-filled carbon material with an electrical conductivity ⁇ 1 in the range between about 0.05 and 20 MS / m.
  • an insert 38 inserted from a material having a significantly higher electrical conductivity ⁇ 2, for example, a copper insert with a conductivity of 56th up to 57 MS / m. This insert is insulated by a thin insulating layer 40 against the base substance 35 of the brush 12.
  • FIG. 2 schematically shows the size of the frequency-dependent impedance Z detected by the measuring device 32 in the section I at the end of the brush life, in section II for the range of entry 38 into the detection range of the sensor 24 to the full coverage of the measuring range through the insert 38, and in section III the value of the sensor 24 measured
  • Impedance Z of a new brush as long as the section 36, or the insert 38 has no influence on the impedance of the sensor 24.
  • FIGS. 3a and 3b the curves of the voltage supplied by the signal generator 34 U and the signal current I shown, the curve in FIG. 3a Section I for a badly worn brush and the course in FIG. 3b in Section III for a new brush.
  • the difference .DELTA.I corresponds to the advanced wear of the brush.
  • FIGS. 4 and 5 show by way of example two different designs of a two-component brush, each having an insert 38 with respect to the ground substance 35 significantly increased electrical conductivity ⁇ 2.
  • the insert 38 with a suitably shaped portion 42 in a dovetail groove 44 of the brush body inserted.
  • the outer dimensions of the insert 38 made of the material of higher conductivity ⁇ 2 are adapted to the dimensions of the brush, so that it can be accommodated freely in the brush holder 18 without hindrance without structural alteration.
  • FIG. 5 which has an insert 38 connected to the base substance 35 of the brush 12 by a riveting 46. Again, the outer geometry of the brush remains unchanged.
  • the insulation between the insert 38 and the base substance 35 of the brush takes place in each case by a suitable insulating coating of the insert 38, on the representation in the FIGS. 4 and 5 has been omitted.
  • the monitoring device according to the invention or the monitoring method according to the invention thus enable a continuous monitoring of brush wear in electric motors in drive or generator applications, in particular caused by different operating conditions different wear of the brushes can be found in good time before their failure.
  • This applies for example, for use in the automotive sector, where a different operation and / or different environmental conditions, such as pollution, can cause a greatly shortened life of the brushes of electrical machines.
  • a gradual warning is made possible by a visual, audible or other warning signal, which gives the user the time and the opportunity to prevent foreseeable disruptions in good time. This can result in significant follow-up costs Surprising failure of the electrical machine and in particular also caused thereby risks, for example in traffic, timely and certainly avoided.

Description

Stand der TechnikState of the art

Die Erfindung geht aus von einer Anordnung zur Überwachung der Abnutzung einer Bürste des Schleifbahn- oder Kommutatorsystems einer elektrischen Maschine, wie sie beispielsweise aus der DE 10257623 A1 bekannt geworden ist. Diese Druckschrift zeigt eine Diagnosevorrichtung zur Ermittlung der Länge von Schleifringbürsten in Schleifbahnanordnungen, beziehungsweise von Kollektoren elektrischer Maschinen. Hierbei ist für die Bestimmung der Bürstenlänge ein induktiver Sensor vorgesehen, welcher mit einer Auswerteeinheit zur Auswertung der Sensorsignale verbunden ist zur Ermittlung eines der Bürstenlänge entsprechenden Wertes. Der induktive Sensor weist eine oder mehrere Spulen auf, welche die Bürste insgesamt umfassen.The invention relates to an arrangement for monitoring the wear of a brush of the slideway or commutator of an electric machine, as for example from the DE 10257623 A1 has become known. This document shows a diagnostic device for determining the length of slip ring brushes in Schleifbahnanordnungen, or collectors of electrical machines. In this case, an inductive sensor is provided for determining the brush length, which is connected to an evaluation unit for evaluating the sensor signals for determining a value corresponding to the brush length. The inductive sensor has one or more coils which comprise the brush as a whole.

Alternativ zu diesem induktiven Prinzip sind optische, kapazitive oder elektrische Sensoren genannt, wobei die elektrische Ermittlung der Bürstenlänge durch Widerstandserkennung nicht kontaktlos sondern durch Abtastung erfolgt.As an alternative to this inductive principle, optical, capacitive or electrical sensors are mentioned, wherein the electrical determination of the brush length by resistance detection is not contactless but by scanning.

Eine weitere bekannte Vorrichtung zur kontaktlosen Überwachung der Bürsten einer elektrischen Maschine ist in der DE 19619733 A beschrieben. Diese Druckschrift offenbart einen Steckbürstenhalter mit einem Gehäuse, in dem eine Bürste gegen eine Federkraft verschiebbar angeordnet und in Kontakt mit einem Schleifring bringbar ist. Der Steckbürstenhalter weist eine Überwachungseinheit auf mit wenigstens einem Sensor, der ab einem vorgegebenen Verschiebeweg der Bürste in Richtung des Schleifrings ein Signal auslöst.Another known device for contactless monitoring of the brushes of an electric machine is in the DE 19619733 A described. This document discloses a brush holder with a housing in which a brush slidably disposed against a spring force and can be brought into contact with a slip ring. The plug brush holder has a monitoring unit with at least one sensor, which triggers a signal from a predetermined displacement of the brush in the direction of the slip ring.

Hierbei ist die Überwachungseinheit, ebenfalls in Form eines induktiven Weggebers, in einem separaten, mit dem Bürstenhalter verschraubten Gehäuse angeordnet. Ein Kern des induktiven Weggebers ist über eine stiftförmige Verlängerung und über ein weiteres, koaxial zur Bürste angeordnetes Verbindungselement mit der Bürste gekoppelt und zusammen mit dieser längsverschiebbar. Eine derartige Anordnung ist aufwendig und erfordert zusätzlichen Bauraum innerhalb der Maschine, wodurch deren Abmessungen vergrößert und die Herstellungskosten deutlich erhöht werden.Here, the monitoring unit, also in the form of an inductive displacement sensor, arranged in a separate, bolted to the brush holder housing. A core of the inductive displacement sensor is coupled via a pin-shaped extension and via a further coaxial with the brush arranged connecting element with the brush and along with this longitudinally displaceable. Such an arrangement is complicated and requires additional space within the machine, which increases their dimensions and the production costs are significantly increased.

Die Offenlegungsschrift SU 729 708 A1 beschreibt eine Überwachungsvorrichtung für die Abnutzung einer in einem Bürstenhalter verschiebbar gelagerten Bürste einer elektrischen Maschine. Dabei ist in einen Bürstenkörper der Bürste ein magnetischer Messabschnitt integriert. Die Offenlegungsschriften SU 756 529 A1 und SU 860 187 A2 beschreiben ähnliche Überwachungsvorrichtungen. Das Dokument US 4,344,072 A betrifft eine Überwachungsvorrichtung für eine Abnutzung einer Bürste einer elektrischen Maschine. Die Überwachungsvorrichtung weist eine erste Bürste auf, welche einen Kommutator kontaktiert. Dabei ist in der ersten Bürste eine zweite Bürste angeordnet, wobei die zweite Bürste gegenüber der ersten Bürste mittels einer Isolierschicht elektrisch isoliert istThe publication SU 729 708 A1 describes a monitoring device for the wear of a slidably mounted in a brush holder brush an electric machine. In this case, a magnetic measuring section is integrated in a brush body of the brush. The publications SU 756 529 A1 and SU 860 187 A2 describe similar monitoring devices. The document US 4,344,072 A relates to a monitoring device for a wear of a brush of an electric machine. The monitoring device has a first brush which contacts a commutator. In this case, a second brush is arranged in the first brush, wherein the second brush is electrically insulated from the first brush by means of an insulating layer

Offenbarung der ErfindungDisclosure of the invention

Der Erfindung liegt die Aufgabe zugrunde, eine Vorrichtung und ein Verfahren zur Überwachung der Abnutzung einer Bürste einer elektrischen Maschine anzugeben, welche betriebssicher arbeiten, mit geringem Kostenaufwand herstellbar sind und keinen oder nur einen geringen zusätzlichen Bauraum in der Maschine erfordern, so dass sie in herkömmliche Bürstensysteme integrierbar oder gegen diese austauschbar sind. Dies wird erreicht durch die kennzeichnenden Merkmale der übergeordneten Vorrichtungs- und Verfahrensansprüche.The invention has for its object to provide an apparatus and a method for monitoring the wear of a brush of an electric machine, which operate reliable, can be produced at low cost and require little or no additional space in the machine, so that they are in conventional Brush systems can be integrated or exchanged for them. This is achieved by the characterizing features of the parent device and method claims.

Zur Erzielung eines deutlich messbaren Impedanzunterschiedes im Messsignal entsprechend dem fortschreitenden Bürstenverschleiß ist es zweckmäßig, wenn die Grundsubstanz der Bürste eine deutlich unterschiedliche, vorzugsweise geringere elektrische Leitfähigkeit γI aufweist als der in die Bürste integrierte Messabschnitt.In order to achieve a clearly measurable impedance difference in the measurement signal in accordance with the progressive brush wear, it is expedient if the base substance of the brush has a significantly different, preferably lower electrical conductivity γI than the measuring section integrated in the brush.

Zweckmäßigerweise besteht hierbei die Grundsubstanz der Bürste aus einem ungefüllten oder aus einem metallgefüllten Kohlematerial mit einem elektrischen Leitwert γI im Bereich zwischen etwa 0,05 und 20 MS/m, während der Einsatz in der Bürste zur deutlichen Abgrenzung des vom Sensor gemessenen Impedanzwertes Z aus Metall, vorzugsweise aus Kupfer mit einem elektrischen Leitwert γ2 von 56 bis 57 MS/m besteht. Bei der Verwendung gut leitfähiger Bürsten kann das Messprinzip jedoch auch umgekehrt werden, indem als Material fair den in die Bürste integrierten Abschnitt mit abweichender elektrischer Leitfähigkeit γ2 gegenüber der Grundsubstanz der Bürste ein Dielektrikum verwendet wird, so dass die Impedanz Z in diesem Messbereich deutlich abfällt gegenüber dem zulässigen Verschleißbereich der Bürste. Weiterhin ist es bei der Erfindung in Kommutatormotoren vorteilhaft, dass der in die Bürste integrierte Abschnitt mit abweichender elektrischer Leitfähigkeit gegenüber der Grundsubstanz der Bürste elektrisch isoliert und nicht von dem Arbeitsstrom der Bürste durchflossen ist, um den Einfluss des Betriebsstromes auf die Impedanzmessung zu verhindern.Expediently, in this case, the base substance of the brush consists of an unfilled or of a metal-filled carbon material with an electrical conductivity γI in the range between about 0.05 and 20 MS / m, while the use in the brush for clear demarcation of the impedance Z measured from the sensor made of metal , preferably made of copper with an electrical conductivity γ2 of 56 to 57 MS / m. However, when using brushes of good conductivity, the measuring principle can also be reversed by using a dielectric as the material that is fairly integrated into the brush with a different electrical conductivity γ2 than the base substance of the brush, so that the impedance Z drops significantly in this measuring range the permissible wear area of the brush. Furthermore, it is advantageous in the invention in commutator motors that the integrated into the brush section with different electrical conductivity with respect to the ground substance of the brush is electrically insulated and not flowed through by the working current of the brush to prevent the influence of the operating current on the impedance measurement.

Unter fertigungstechnischen Gesichtspunkten kann es vorteilhaft sein, wenn der Abschnitt mit dem von der Grundsubstanz der Bürste abweichenden elektrischen Leitwert getrennt von der Bürste hergestellt und durch eine formschlüssige, vorzugsweise schwalbenschwanzförmige Verbindung nachträglich auf der Bürste montiert wird. Die Verbindung zwischen dem Einsatz
und der Bürste kann auch durch Kleben hergestellt werden, sodass hinsichtlich der Gestaltung der zu verbindenden Teile kein oder nahezu kein zusätzlicher Aufwand entsteht. Andererseits kann auch eine formschlüssige Verbindung durch eine Klebeverbindung zusätzlich gesichert werden. Bei starken mechanischen Beanspruchungen der Bürste, beispielsweise in Antrieben mit starken Vibrationen, ist eine Nietverbindung zwischen der Bürste und dem Einsatz vorteilhaft. Bei Verwendung geeigneter Materialien für die Grundsubstanz der Bürste und für den Abschnitt mit abweichender elektrischer Leitfähigkeit ist jedoch auch die Herstellung der Bürste in einem Arbeitsgang, vorzugsweise durch gemeinsames Verpressen der unterschiedlichen Materialien möglich.From a manufacturing point of view, it may be advantageous if the section made with the deviating from the basic substance of the brush electrical conductance separately from the brush and subsequently mounted by a positive, preferably dovetailed connection on the brush. The connection between the mission
and the brush can also be made by gluing, so that with regard to the design of the parts to be joined no or almost no additional effort. On the other hand, a positive connection can be additionally secured by an adhesive connection. In the case of heavy mechanical stresses on the brush, for example in drives with strong vibrations, a riveted connection between the brush and the insert is advantageous. When using suitable materials for the base substance of the brush and the section with different electrical conductivity but also the production of the brush in a single operation, preferably by co-pressing the different materials is possible.

In konstruktiver Hinsicht ist es zweckmäßig, wenn der Impedanzsensor von der Auswerteeinheit baulich getrennt und als kompakte Einheit direkt in den Bürstenhalter integriert ist. In die Auswerteeinheit kann vorteilhafterweise ein Signalgeber für die Speisung des Sensors mit einer Wechselspannung U integriert werden. Eine derartige Anordnung ist konstruktiv sehr variabel und lässt sich leicht ohne nennenswerten zusätzlichen Platzbedarf im Bürstenbereich der Maschine einbauen.In terms of design, it is expedient if the impedance sensor is structurally separated from the evaluation unit and integrated as a compact unit directly into the brush holder. In the evaluation unit advantageously a signal generator for the supply of the sensor with an AC voltage U can be integrated. Such an arrangement is structurally very variable and can be easily installed without significant additional space in the brush area of the machine.

Das erfindungsgemäße Verfahren zur Überwachung der Abnutzung einer Bürste des Schleifbahn- oder Kommutatorsystems einer elektrischen Maschine zeichnet sich dadurch aus, dass ein ortsfest angeordneter Impedanzsensor mit einer Wechselspannung U oder einer Signalfolge im Frequenzbereich von 100 kHz bis 30 MHz, vorzugsweise in einem Bereich von 500 kHz bis 3MHz gespeist wird. Entsprechend dem Leitwert γ1,γ2 eines dem Sensor benachbarten Abschnittes der verschiebbaren Bürste liefert der Sensor hieraus ein veränderliches Impedanzsignal als Maß für die verbleibende Bürstenlänge an eine Auswerteeinheit. Dieses Verfahren ist bei geringem zusätzlichem Aufwand sehr betriebssicher und gewährleistet ein mit einfachen Mitteln leicht erfassbares Messsignal für die Abnützung der Bürste, sodass herkömmliche Schwierigkeiten durch einen unvorhergesehenen Bürstenausfall vermieden werden. In einigen Applikationen wird hierbei die Bürste durch das Ausgangssignal der Auswerteeinheit von der Spannungsversorgung abgeschaltet, sobald ein vorgegebener Signalpegel überschritten wird. Hierdurch ist sichergestellt, dass in kritischen Anwendungen Folgeschäden sicher vermieden werden.The inventive method for monitoring the wear of a brush of the slideway or Kommutatorsystems an electrical machine is characterized in that a fixedly arranged impedance sensor with an AC voltage U or a signal sequence in the frequency range of 100 kHz to 30 MHz, preferably in a range of 500 kHz is fed to 3MHz. In accordance with the conductance γ1, γ2 of a section of the displaceable brush adjacent to the sensor, the sensor supplies therefrom a variable impedance signal as a measure of the remaining brush length to an evaluation unit. This method is very reliable with little additional effort and ensures an easily detectable by simple means measuring signal for the wear of the brush, so that conventional difficulties are avoided by an unforeseen brush failure. In some applications, the brush is turned off by the output of the evaluation of the power supply, as soon as a predetermined signal level is exceeded. This ensures that consequential damage is safely avoided in critical applications.

Weitere Einzelheiten und vorteilhafte Ausgestaltungen der Erfindung ergeben sich aus den Unteransprüchen und der Beschreibung von Ausführungsbeispielen.Further details and advantageous embodiments of the invention will become apparent from the dependent claims and the description of exemplary embodiments.

Die Zeichnung zeigt

  • in Figur 1 eine Prinzipdarstellung der erfindungsgemäßen Überwachungsvorrichtung, teilweise im Schnitt,
  • in Figur 2 die Veränderung des mit zunehmendem Verschleiß der Bürste gemessenen Impedanzwertes Z,
  • in Figur 3 den Verlauf eines eingespeisten Wechselspannungssignals und den jeweiligen Strom I durch den Impedanzsensor, in der Darstellung 3a bei hohem Impedanzwert Z entsprechend einem hohen elektrischen Leitwert in der Bürste und in der Darstellung 3b bei einem niedrigen Impedanzwert Z entsprechend einem niedrigen elektrischen Leitwert des zum Impedanzsensor benachbarten Bürstenteils,
  • in Figur 4 ein Beispiel für eine formschlüssige Verbindung zwischen dem Grundkörper einer Bürste und einem Einsatz aus einem Material mit abweichendem elektrischen Leitwert und
  • in Figur 5 ein weiteres Beispiel einer Bürste mit einem durch eine Nietverbindung am Bürstengrundkörper befestigten Einsatz aus einem Material mit abweichendem elektrischem Leitwert.
The drawing shows
  • in FIG. 1 a schematic diagram of the monitoring device according to the invention, partly in section,
  • in FIG. 2 the change in the impedance value Z measured with increasing wear of the brush,
  • in FIG. 3 the course of an injected AC signal and the respective current I through the impedance sensor, in the representation 3a at high impedance value Z corresponding to a high electrical conductance in the brush and in the representation 3b at a low impedance value Z corresponding to a low electrical conductance of the adjacent brush to the impedance sensor part .
  • in FIG. 4 an example of a positive connection between the body of a brush and a use of a material with different electrical conductance and
  • in FIG. 5 a further example of a brush with an attached by a rivet on the brush body insert made of a material with a different electrical conductance.

In Figur 1 ist mit 10 ein Schleifring oder Kommutator einer nicht weiter dargestellten elektrischen Maschine bezeichnet, welcher über eine Bürste 12 und eine Litze 13 mit dem Pluspol 14 eines Gleichspannungsnetzes verbunden ist. Die Bürste 12 ist in einem Bürstenhalter 18 zum Kommutator oder Schleifring 10 hin längsverschiebbar gehalten und wird durch eine Feder 20, welche auf einem Fortsatz 22 der Bürste 12 zentriert ist, an den Schleifring oder Kommutator 10 angedrückt. Der Minuspol 16 des Gleichspannungsnetzes ist an eine weitere, nur schematisch eingezeichnete Bürste angeschlossen, welche gleichartig ausgebildet und gehalten ist.In FIG. 1 is denoted by 10 a slip ring or commutator of an electric machine, not shown, which is connected via a brush 12 and a wire 13 to the positive terminal 14 of a DC voltage network. The brush 12 is held longitudinally displaceable in a brush holder 18 to the commutator or slip ring 10 and is pressed by a spring 20 which is centered on an extension 22 of the brush 12 to the slip ring or commutator 10. The negative terminal 16 of the DC voltage network is connected to a further, only schematically drawn brush, which is designed and maintained similar.

Die Überwachungsvorrichtung für die Abnutzung der Bürste 12 weist eine kontaktlose Sensoreinrichtung auf in Form eines Impedanzsensors 24 mit einer Spule 26 und einem E-förmigen Magnetkern 28, welcher ortsfest unmittelbar der Bürste 12 benachbart angeordnet ist und zur Bürste hin keinen geschlossenen Magnetkreis aufweist. Der Impedanzsensor 24 ist mit einer Auswerteeinheit 30 verbunden, welche eine Impedanzmesseinrichtung 32 sowie einen Signalgeber 34 enthält zur Speisung der Spule 26 mit einer hochfrequenten Spannung U. Die dem Impedanzsensor 24 unmittelbar benachbarte, in dem Bürstenhalter 18 längsverschiebbar geführte Bürste 12 ist als Zweikomponentenbauteil ausgeführt. Sie besteht im Wesentlichen aus einem ungefüllten oder teilweise metallgefüllten Kohlematerial mit einer elektrischen Leitfähigkeit γ1 im Bereich zwischen etwa 0,05 und 20 MS/m. Im oberen, von der Kontaktfläche zum Schleifring oder Kommutator 10 abgewandten Abschnitt 36 ist in den dem Impedanzsensor 24 benachbarter Außenbereich der Bürste 12 ein Einsatz 38 eingefügt aus einem Material mit deutlich höherer elektrischer Leitfähigkeit γ2, zum Beispiel ein Einsatz aus Kupfer mit einer Leitfähigkeit von 56 bis 57 MS/m. Dieser Einsatz ist durch eine dünne Isolierschicht 40 gegenüber der Grundsubstanz 35 der Bürste 12 isoliert.The monitoring device for the wear of the brush 12 has a contactless sensor device in the form of an impedance sensor 24 with a coil 26 and an E-shaped magnetic core 28, which is arranged directly adjacent to the brush 12 adjacent and the brush has no closed magnetic circuit. The impedance sensor 24 is connected to an evaluation unit 30, which includes an impedance measuring device 32 and a signal generator 34 for feeding the coil 26 with a high-frequency voltage U. The immediately adjacent to the impedance sensor 24, in the brush holder 18 longitudinally guided brush 12 is designed as a two-component component. It consists essentially of an unfilled or partially metal-filled carbon material with an electrical conductivity γ1 in the range between about 0.05 and 20 MS / m. In the upper, facing away from the contact surface to the slip ring or commutator 10 section 36 is in the impedance sensor 24 adjacent outer region of the brush 12, an insert 38 inserted from a material having a significantly higher electrical conductivity γ2, for example, a copper insert with a conductivity of 56th up to 57 MS / m. This insert is insulated by a thin insulating layer 40 against the base substance 35 of the brush 12.

Die Vorrichtung arbeitet folgendermaßen:

  • Durch die von dem Signalgeber 34 in die Spule 26 eingespeiste hochfrequente Spannung U werden in der Bürste 12 Wirbelströme erzeugt, deren Höhe von der Leitfähigkeit y des Bürstenmaterials abhängt. Unterschiedliche Wirbelströme in der Bürste beeinflussen die Impedanz Z des Sensors 24, da die Feldlinien der Spule 26 teilweise in der Bürste 12 verlaufen. Diese Tatsache macht sich die erfindungsgemäße Überwachungsvorrichtung, beziehungsweise das erfindungsgemäße Überwachungsverfahren für die Abnutzung der Bürste zunutze. Mit zunehmender Abnutzung der Bürste 12 gelangt der Einsatz 38, beziehungsweise der Abschnitt 36 mit dem Material mit höherer elektrischer Leitfähigkeit γ2 in den Bereich der Feldlinien des Sensors 24. Hierdurch nehmen die von der Spule 26 erzeugten Wirbelströme zu und mit ihnen die Impedanz Z des Sensors 24, welche in der Messeinrichtung 32 der Auswerteeinheit 30 erfasst und als vorzugsweise digitales Signal 48 zum Beispiel an eine nicht dargestellte Diagnoseeinheit ausgegeben wird.
The device works as follows:
  • By the high-frequency voltage U fed by the signal generator 34 into the coil 26, eddy currents are generated in the brush 12 whose height depends on the conductivity y of the brush material. Different eddy currents in the brush affect the impedance Z of the sensor 24, since the field lines of the coil 26 extend partially in the brush 12. This fact makes use of the monitoring device according to the invention or the monitoring method according to the invention for the wear of the brush. With increasing wear of the brush 12, the insert 38, or the portion 36 with the material with higher electrical conductivity γ2 reaches the area of the field lines of the sensor 24. As a result, the eddy currents generated by the coil 26 and with them the impedance Z of the sensor 24, which is detected in the measuring device 32 of the evaluation unit 30 and output as a preferably digital signal 48, for example, to a diagnostic unit, not shown.

Dieser Sachverhalt ist in den Abbildungen der Figuren 2 und 3 näher dargestellt. Figur 2 zeigt schematisch die Größe der durch die Messeinrichtung 32 erfassten frequenzabhängigen Impedanz Z im Abschnitt I am Ende der Bürstenlebensdauer, im Abschnitt II für den Bereich des Eintritts des Einsatzes 38 in den Erfassungsbereich des Sensors 24 bis zur vollständigen Überdeckung des Messbereiches durch den Einsatz 38, und im Abschnitt III den Wert der vom Sensor 24 gemessenenThis fact is in the pictures of the FIGS. 2 and 3 shown in more detail. FIG. 2 schematically shows the size of the frequency-dependent impedance Z detected by the measuring device 32 in the section I at the end of the brush life, in section II for the range of entry 38 into the detection range of the sensor 24 to the full coverage of the measuring range through the insert 38, and in section III the value of the sensor 24 measured

Impedanz Z einer neuwertigen Bürste, solange der Abschnitt 36, beziehungsweise der Einsatz 38 keinen Einfluss auf die Impedanz des Sensors 24 hat.Impedance Z of a new brush, as long as the section 36, or the insert 38 has no influence on the impedance of the sensor 24.

Entsprechend den Kennlinienabschnitten I und III in Figur 2 sind in den Figuren 3a und 3b die Verläufe der vom Signalgeber 34 gelieferten Spannung U und des Signalstromes I dargestellt, wobei der Kurvenverlauf in Figur 3a dem Abschnitt I für eine stark abgenutzte Bürste und der Verlauf in Figur 3b dem Abschnitt III für eine neuwertige Bürste entspricht. Der Unterschied ΔI entspricht jeweils dem fortgeschrittenen Verschleiß der Bürste.According to the characteristic sections I and III in FIG. 2 are in the FIGS. 3a and 3b the curves of the voltage supplied by the signal generator 34 U and the signal current I shown, the curve in FIG. 3a Section I for a badly worn brush and the course in FIG. 3b in Section III for a new brush. The difference .DELTA.I corresponds to the advanced wear of the brush.

Die Figuren 4 und 5 zeigen beispielhaft zwei unterschiedliche Bauformen einer Zweikomponentenbürste, welche jeweils einen Einsatz 38 mit gegenüber der Grundsubstanz 35 deutlich erhöhter elektrischer Leitfähigkeit γ2 aufweisen. Bei der Ausführungsform gemäß Figur 4 ist der Einsatz 38 mit einem passend geformten Abschnitt 42 in eine schwalbenschwanzförmige Nut 44 des Bürstengrundkörpers einschiebbar. Die äußeren Abmessungen des Einsatzes 38 aus dem Material höherer Leitfähigkeit γ2 sind auf die Abmessungen der Bürste abgestimmt, so dass diese ungehindert ohne bauliche Veränderung längsverschiebbar in dem Bürstenhalter 18 aufgenommen werden kann. Entsprechendes gilt für die Figur 5, welche einen durch eine Nietung 46 mit der Grundsubstanz 35 der Bürste 12 verbundenen Einsatz 38 aufweist. Auch hierbei bleibt die äußere Geometrie der Bürste unverändert. Die Isolation zwischen dem Einsatz 38 und der Grundsubstanz 35 der Bürste erfolgt jeweils durch eine geeignete isolierende Beschichtung des Einsatzes 38, auf deren Darstellung in den Figuren 4 und 5 verzichtet worden ist.The FIGS. 4 and 5 show by way of example two different designs of a two-component brush, each having an insert 38 with respect to the ground substance 35 significantly increased electrical conductivity γ2. In the embodiment according to FIG. 4 the insert 38 with a suitably shaped portion 42 in a dovetail groove 44 of the brush body inserted. The outer dimensions of the insert 38 made of the material of higher conductivity γ2 are adapted to the dimensions of the brush, so that it can be accommodated freely in the brush holder 18 without hindrance without structural alteration. The same applies to the FIG. 5 which has an insert 38 connected to the base substance 35 of the brush 12 by a riveting 46. Again, the outer geometry of the brush remains unchanged. The insulation between the insert 38 and the base substance 35 of the brush takes place in each case by a suitable insulating coating of the insert 38, on the representation in the FIGS. 4 and 5 has been omitted.

Die erfindungsgemäße Überwachungsvorrichtung, beziehungsweise das erfindungsgemäße Überwachungsverfahren ermöglichen somit eine dauernde Überwachung des Bürstenverschleißes bei Elektromotoren in Antriebs- oder Generatorapplikationen, wobei insbesondere ein durch unterschiedliche Betriebsbedingungen verursachter unterschiedlicher Verschleiß der Bürsten rechtzeitig vor deren Ausfall festgestellt werden kann. Dies gilt beispielsweise für den Einsatz im Automobilbereich, wo ein unterschiedlicher Betrieb und/oder unterschiedliche Umweltbedingungen, beispielsweise durch Verschmutzung, eine stark verkürzte Lebensdauer der Bürsten von elektrischen Maschinen verursachen können. Insbesondere wird eine gestufte Vorwarnung durch ein optisches, akustisches oder sonstiges Warnsignal ermöglicht, welche dem Benutzer die Zeit und die Möglichkeit gibt, absehbaren Störungen rechtzeitig vorzubeugen. Hierdurch können erhebliche Folgekosten durch einen überraschenden Ausfall der elektrischen Maschine und insbesondere auch hierdurch verursachte Risiken, beispielsweise im Verkehr, rechtzeitig und mit Sicherheit vermieden werden.The monitoring device according to the invention, or the monitoring method according to the invention thus enable a continuous monitoring of brush wear in electric motors in drive or generator applications, in particular caused by different operating conditions different wear of the brushes can be found in good time before their failure. This applies, for example, for use in the automotive sector, where a different operation and / or different environmental conditions, such as pollution, can cause a greatly shortened life of the brushes of electrical machines. In particular, a gradual warning is made possible by a visual, audible or other warning signal, which gives the user the time and the opportunity to prevent foreseeable disruptions in good time. This can result in significant follow-up costs Surprising failure of the electrical machine and in particular also caused thereby risks, for example in traffic, timely and certainly avoided.

Claims (12)

  1. Brush for a sliding-track or commutator system of an electrical machine, comprising a monitoring apparatus for wear of the brush, comprising a contactless sensor device for ascertaining the brush length and comprising an evaluation unit (30) which has an impedance measuring device (32) and a signal transmitter (34), wherein the sensor device is an impedance sensor (24) which is connected to the evaluation unit (30), and wherein the impedance sensor (24) has a magnet core (28) and a coil (26) and is connected to the signal transmitter (34) for generating an alternating current (I) in the impedance sensor (24), and wherein the impedance sensor (24) is arranged fixed in position and adjacent to the brush (12) which can be displaced in a brush holder (18), characterized in that at least one section (36, 38) of the brush (12) has an electrical conductivity (γ2) which differs from the conductivity (γ1) of the main substance (35) of the brush (12), and wherein the section (36, 38) which is integrated into the brush (12) and has a different electrical conductivity (γ2) from the main substance (35) of the brush (12) is electrically insulated, and wherein a change in the conductivity can be detected by the impedance sensor (24), wherein, in the impedance measuring device (32), an impedance (Z) of the impedance sensor (24) can be detected and can be output to a diagnosis unit as a digital signal (48).
  2. Brush comprising a monitoring apparatus according to Claim 1, characterized in that the main substance (35) of the brush (12) has a considerably lower electrical conductivity (γ1) than the section (36, 38) which is integrated into the brush (12).
  3. Brush comprising a monitoring apparatus according to either of the preceding claims, characterized in that the main substance (35) of the brush (12) is composed of an unfilled or a metal-filled carbon material and the insert (38) is composed of metal, preferably of copper.
  4. Brush comprising a monitoring apparatus according to one of the preceding claims, characterized in that the impedance sensor (24) is integrated into the brush holder (18) and is arranged fixed in position in relation to the said brush holder and in relation to the sliding-track or commutator system.
  5. Brush comprising a monitoring apparatus according to one of the preceding claims, characterized in that the section (36, 38) with the electrical conductance (γ2) which differs from the main substance (35) of the brush (12) is arranged on the circumference of the brush (12) in the end region of the permissible brush displacement.
  6. Brush comprising a monitoring apparatus according to one of the preceding claims, characterized in that the section (36, 38) with the electrical conductance (γ2) which differs from the main substance (35) of the brush (12) is produced separately and is fastened to the brush (12) by an interlocking, preferably dovetail-like connection (42, 44) and/or by adhesive bonding and/or by a rivet connection (46).
  7. Brush comprising a monitoring apparatus according to one of Claims 1 to 5, characterized in that, during production of the brush (12), the section (36, 38) with the electrical conductance (γ2) which differs from the main substance (35) of the brush (12) is shaped, preferably compressed, together with the material (γ1) of the main substance (35) in one working step in order to form the finished brush (12).
  8. Method for monitoring wear of a brush of the sliding-track or commutator system of an electrical machine, wherein a contactless sensor device supplies a signal which corresponds to brush wear to an evaluation unit, characterized in that an impedance sensor (24), which is arranged fixed in position, receives a signal (U, I) from a signal transmitter (34) and, in accordance with the conductance (γ1, γ2) of a section (36, 38), which is adjacent to the sensor (24), of the displaceable brush (12), supplies a variable impedance signal (Z) as a measure of wear of the brush (12) and/or of the remaining brush length to the evaluation unit (30), wherein an impedance (Z) of the impedance sensor (24) is detected and output to a diagnosis unit as a digital signal (48) by a measuring device (32) in the evaluation unit (30), and wherein a section (36, 38) which is integrated into the brush (12) and has a different electrical conductivity to a main substance (35) of the brush (12) is electrically insulated and a working current of the brush (12) does not flow through the said section.
  9. Method according to Claim 8, characterized in that the brush (12) is disconnected from the voltage supply (14, 16) by the output signal (48) of the evaluation unit (30) as soon as a prespecified threshold value of the impedance signal (Z) is exceeded.
  10. Method according to Claim 8 or 9, characterized in that monitoring of brush wear is performed over the long term in accordance with the displacement of the brush (12) in relation to the brush holder (18).
  11. Method according to one of Claims 8 to 10, characterized in that the impedance sensor (24) supplies a stepped and/or continuously variable measurement signal (Z) as a measure of brush wear to the evaluation unit (30).
  12. Method according to one of Claims 8 to 11, characterized in that the evaluation unit (30) of the impedance sensor (24) supplies a preferably digital signal (48) as a control signal to a diagnosis unit and/or to a display instrument of a motor vehicle.
EP06125064.3A 2005-12-22 2006-11-30 Brush for a sliding-track or commutator system of an electrical machine with a monitoring apparatus for wear of the brush and a method for monitoring the wear of a brush Active EP1801938B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102005061412A DE102005061412A1 (en) 2005-12-22 2005-12-22 Apparatus and method for monitoring the wear of a brush

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EP1801938A2 EP1801938A2 (en) 2007-06-27
EP1801938A3 EP1801938A3 (en) 2014-04-23
EP1801938B1 true EP1801938B1 (en) 2017-12-27

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GB201104155D0 (en) * 2011-03-11 2011-04-27 Esdaco Bvba Apparatus for monitoring of brushes in particular slipring or commutator brushes, on electrical machines
DE102011088500B4 (en) * 2011-12-14 2013-06-27 Robert Bosch Gmbh Electric machine for a motor vehicle
JP6116159B2 (en) 2012-08-27 2017-04-19 キヤノン株式会社 Slip ring, slip ring electrical system, and robot
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DE102014226322A1 (en) 2014-12-17 2016-06-23 Zf Friedrichshafen Ag Brush wear in the DC motor
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