ECS Solutions

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Systems/Assemblies
RFI-EMI (Noise Suppression)

Product Solutions: Greater than the Sum of Our Parts

Brushes + Commutators + Magnets = Solutions (Assemblies / Systems)

ECS offers fully integrated systems that combine its core products and technologies – Brushes, Commutators, Magnets, Design, Test and Measurement – to yield comprehensive solutions tailored to reduce costs and increase efficiencies.

Solution Examples: Magnetic Commutator | Cost Reduction through Design | Molded Magnet Assemblies

Example: Magnetic Commutator (US Patent Issued to ECS in June’05)

The typical Motor Manufacturing Process: • Magnet Ring and Commutator are manufactured and assembled separately. • Due to inherent weakness of the Magnet Ring, ID bushing, and sometimes, plastic sleeves are required. • Extra length on the armature assembly is required to accommodate the “stacking” of the individual components.
The Magnetic Commutator Alternative: • The magnet is an integral part of the commutator. • Over molding a “green magnetic preform” with compatible resins “attaches” magnet to commutator. • Magnetic Commutator bore mounts to the shaft without separate assembly operations for the magnet and the commutator. • “All in One” Magnetic Commutator requires less shaft length.
The “green magnetic preform” is “captured” during the over molding process.
Fit, form and function is identical as a commutator and magnet ring assembled individually.

Example: Cost Reduce Typical Motor Design

Typical Motor Design

Materials
2 - shunted carbon brushes
2 - torsion springs
2 - brush boxes
2 - insulator clips
2 - lead wires
4 - lead wire terminals
14 total components

Labor
2 - Insert brush clip assembly into end cap
2 - Plug lead wire into clip assembly
4 - assembly steps

parts layout

ECS Brush Card Assembly

Materials
1 - brush holder
2 - shunted carbon brushes
2 - coil springs
2 - lead wires
2 - lead wire terminals (to switch)
9 total components

Labor
1 - Insert brush card
1 - assembly step

Example: Insert Over Molded Magnet Assemblies

Typical Assembly Methods (Glue, Clips, etc.)

• Retention component required – glue, clips, etc.
• Assembly is labor intensive.
• Potential to damage/chip magnet during installation of retention system
• Retention components can fail.

Insert Over Molded Assembly

• Fewer parts required.
• Less assembly steps required.
• Reduced chance of magnet being damaged during insertion.
• Ferrite and rare earth magnets.
• Improved corrosion resistance