Granted Patent B2

US 12,418,151 · App. 18/660,394 · Granted Sep 16, 2025

Inventors: Robert S. Cutsforth (Bellingham, WA); Dustin L. Cutsforth (Leawood, KS); Douglas Christopher Bruey (Seattle, WA); Michael Lee Schaaf (Seattle, WA); David William Drury Harrison (Seattle, WA)

Assignee: CUTSFORTH, INC.

H01R39/58G01B21/22H01R39/26H01R39/38H02K11/20

Abstract

Claims (39)

1. A system for monitoring the wear state of a carbon brush, comprising:

a carbon brush having an upper surface, a lower surface opposite the upper surface, and a length measured from the upper surface to the lower surface, wherein the length is diminished from an initial length as the lower surface of the carbon brush wears away during use;

a spring having a coiled portion and an elongate portion extending from the coiled portion, wherein the spring is configured to provide a force urging the lower surface of the carbon brush into contact with a rotating conductive surface of an electrical machine;

a spacer coupled to the upper surface of the carbon brush, the spacer positioned between the coiled portion of the spring and the upper surface of the carbon brush; and

a wear state monitor including a sensor, wherein the sensor is configured to measure an amount of diminution in the length of the carbon brush from its initial length as the lower surface of the carbon brush wears away during use;

wherein the wear state monitor is configured to detect an angular position of the sensor to a magnet.

2. The system of claim 1 , wherein the spacer includes an engagement feature configured to mate with a complementary engagement feature in the upper surface of the carbon brush.

3. The system of claim 1 , wherein the spacer includes a pin configured to extend into a bore located within the upper surface of the carbon brush.

4. The system of claim 1 , wherein the sensor measures an angular displacement of the coiled portion of the spring.

5. The system of claim 1 , wherein the sensor is positioned within the coiled portion of the spring.

6. The system of claim 1 , wherein the sensor is configured to sense a change in a magnetic field created by the magnet.

7. The system of claim 1 , wherein the wear state monitor is positioned in the coiled portion of the spring.

8. The system of claim 1 , wherein the spacer defines a concave cradle, wherein the coiled portion of the spring rests in the cradle.

9. The system of claim 1 , wherein the sensor is configured to transmit a wireless signal to a site monitor, and wherein the wireless signal is configured to provide information relating to diminution in length of the carbon brush.

10. A system for monitoring the wear state of a carbon brush, comprising:

a carbon brush having an upper surface, a lower surface opposite the upper surface, and a length measured from the upper surface to the lower surface, wherein the length is diminished from an initial length as the lower surface of the carbon brush wears away during use;

a spring having a coiled portion and an elongate portion extending from the coiled portion, wherein the spring is configured to provide a force urging the lower surface of the carbon brush into contact with a rotating conductive surface of an electrical machine;

a spacer coupled to the upper surface of the carbon brush, the spacer positioned between the coiled portion of the spring and the upper surface of the carbon brush; and

a wear state monitor including a sensor, wherein the sensor is configured to measure an amount of diminution in the length of the carbon brush from its initial length as the lower surface of the carbon brush wears away during use;

wherein the sensor includes an accelerometer configured to sense dynamic vibration of the carbon brush.

11. The system of claim 1 , wherein the wear state monitor is configured to rotate through an arc angle as the carbon brush wears away, and wherein the arc angle correlates to the amount the carbon brush wears away.

12. The system of claim 1 , wherein the wear state monitor rotates about an axis of rotation, wherein the axis of rotation is a fixed distance from an upper surface of the carbon brush as the wear state monitor rotates.

13. A system for monitoring the wear state of a carbon brush, comprising:

a carbon brush having an upper surface, a lower surface opposite the upper surface, and a length measured from the upper surface to the lower surface, wherein the length is diminished from an initial length as the lower surface of the carbon brush wears away during use;

a spring having a coiled portion and an elongate portion extending from the coiled portion, wherein the spring is configured to provide a force urging the lower surface of the carbon brush into contact with a rotating conductive surface of an electrical machine;

a spacer coupled to the upper surface of the carbon brush, the spacer positioned between the coiled portion of the spring and the upper surface of the carbon brush; and

a wear state monitor including a sensor, wherein the sensor is configured to measure an amount of diminution in the length of the carbon brush from its initial length as the lower surface of the carbon brush wears away during use;

wherein the spacer defines a concave cradle, wherein the coiled portion of the spring rests in the cradle;

wherein the spacer includes a pin configured to extend into a bore located within the upper surface of the carbon brush;

wherein the wear state monitor is configured to detect an angular position of the sensor to a magnet.

14. The system of claim 13 , wherein the sensor measures an angular displacement of the coiled portion of the spring.

15. The system of claim 13 , wherein the sensor is configured to sense a change in a magnetic field created by the magnet.

16. The system of claim 13 , wherein the sensor is configured to transmit a wireless signal to a site monitor, and wherein the wireless signal is configured to provide information relating to diminution in length of the carbon brush.

17. A method for monitoring the wear state of a carbon brush, the method comprising:

detecting an angular position of a sensor to a magnet by sensing a change in a magnetic field created by the magnet with the sensor;

determining an angular displacement of a coiled portion of a spring of a brush holder assembly based on the change in the magnetic field sensed by the sensor as a length of a carbon brush of the brush holder assembly diminishes during use, wherein the spring is configured to provide a force urging the carbon brush into contact with a rotating conductive surface of an electrical machine; and

determining a wear state of the carbon brush based on the angular displacement of the coiled portion of the spring.

18. The method of claim 17 , further comprising a spacer positioned between the coiled portion of the spring and the carbon brush.

19. The method of claim 18 , wherein the spacer defines a concave cradle, wherein the coiled portion of the spring rests in the cradle.

Continuity (4)

References Cited (241)