Hello All,

Hello Dear Friend Alex, (and btw, congratulations on the great Futbol Game today, where Netherlands won!!)

Ok, like I posted last night, here are some 3D CAD Images on How to CLOCK the TENSION SPRING to ADJUST BRUSH PUSH FORCE.

BUT FIRST, I WOULD LIKE TO EMPHASIZE ABOUT TORSION SPRING END TO BRUSH REAR, MUST BE ON THE DEAD CENTER OF BACK END BRUSH FACE!!

THEREFORE, ALL IMAGES HERE HAVE THE BRUSH CENTER LINES SHOWN CLEARLY, SPRING POSITIONING VERSUS BRUSH CENTER LINES.

THIS IS "A MUST BE OPTION" in order that force exerted by spring acts exactly on back end center of brush, to AVOID BRUSH EMBODIMENT LEANING ON EITHER HOUSING INNER WALLS.



Ok, so as you can clearly see on FIRST TWO IMAGES...

We can adjust the Torsion Spring Acting Push Force against Brush, by simply Rotating Upper Pin Slot with a Flat Screwdriver...

Now, in order NOT TO COMPLICATE UNDERSTANDING HERE...I will NOT ENTER -this time- into CW or CCW TURNS of Screwdriver.

Therefore, to understand this Adjustment MUCH EASIER, You will need to PAY ATTENTION TO WHAT OUR PIN TURNING WOULD DO TO SPRING:

• When we Rotate Pin according to the Green Arrows, we will be be WINDING SPRING MORE. (+Force)
• Therefore, ADDING MORE PRESSURE to its EXECUTING END at Brush Rear Face.

As the Opposite takes place when we would be:

• Rotating SPRING PIN following the Red Arrows Direction, we will be UNWINDING SPRING. (- Force)
• Therefore, TAKING AWAY SPRING PRESSURE to the Brush.

Calling for CW or CCW here will complicate the understanding as to "from where should I look at?"

Plus, ALL these Torsion Springs are NOT WOUND THE SAME WAY, because when you want the Spring and Pin Assembly to be at the other side of Brush Housing...Then, that same Spring -shown here- will NOT WORK!!

It MUST BE WOUND OPPOSITE to the one you are seeing on these images...

I hope these 3D CAD Drawings keep ENLIGHTENING your understanding of this Brush Assembly.

Regards

Ufopolitics

EDIT 1: It is very obvious that in order to TURN TORSION SPRING PIN ON EITHER DIRECTIONS, the UPPER PIN NUT needs to be loosen up, (just a bit) You may need to hold lower Pin secure with a Phillips Screwdriver.
PLUS the other side Bolt & Nut MUST BE VERY TIGHT, when loosening the Pin Nut, or else the whole assembly will turn!!

Reply to Message # 855 Brush Embodiment Dual function torsion spring

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@ All, dear friend Ufopolitics,
After carefully reviewing all the latest guidance from Ufopolitics, I have updated the rotor brush assembly and created this new engineering rendering to reflect the intended design as accurately as possible.
Main Features Included

• Vertical round torsion spring (not a horizontal compression spring or flat clock spring).
• Dual-function torsion spring pin, acting as both:
  
  • the spring support and locking pin, and
  • the mounting fastener for the brush holder to the rotor plate.
• Upper slotted spring pin, allowing preload adjustment with a standard flat screwdriver.
• Adjustable brush force by rotating the spring pin:
  
  • Winding the spring increases brush pressure.
  • Unwinding the spring decreases brush pressure.
• "V" shaped spring push end contacting the exact center of the rear brush face, ensuring that the brush remains perfectly aligned and does not lean against the housing walls.
• Exploded assembly view, front/rear views, side alignment view, and pin detail with reference dimensions and component identification.

The intention of this rendering is to provide a simple, builder-friendly engineering reference that follows the latest published concept while making the assembly sequence and adjustment procedure easy to understand.

As always, I welcome comments and corrections from Ufopolitics and other builders so that the final design remains faithful to the original concept and can serve as a common reference for everyone building this machine.

Best regards, Alex (kampen)

@ All,

Attached is the latest engineering rendering of the rotor brush assembly with reference dimensions in millimeters.

This version includes the full component layout for fabrication:
• Dual-function torsion spring pin
• Vertical torsion spring with rounded V-shaped brush push end
• Upper and lower brass brush housing plates
• Carbon brush dimensions
• Second mounting bolt
• Lock washer and nylon lock nut
• Exploded assembly view
• Side/front/rear views
• Spring preload adjustment method.

Important design points included in this rendering:
The torsion spring pin has a dual function. It supports and locks the torsion spring, and also acts as one of the fastening points securing the brush holder to the rotor plate.
The torsion spring push end must be formed in a rounded V shape and must contact the exact center of the rear brush face. 
This is important to avoid side loading or brush leaning inside the housing.

Spring pressure can be adjusted by loosening the spring pin nut slightly and rotating the slotted pin with a flat screwdriver. 
Turning the pin to wind the spring increases brush pressure, while turning it in the opposite direction reduces pressure.

All dimensions shown are reference dimensions and may need to be adjusted to match the final rotor plate, brush size, commutator geometry, and available materials.

Many thanks to Ufopolitics for the detailed explanations and CAD references that helped refine this builder-friendly brush assembly.

Regards, Alex (kampen)

Hello dear friend @kampen ,

Thanks again about your very well done Engineering Renderings!!

However, I have taken the time to download your latest image, in order to CORRECT some images and descriptions which are different from the right ones...
As I can not understand why the program make these "ASSUMPTIONS" that completely differ from your ORIGINAL Rendered Images?



OK, SO, all GREEN AREAS are your perfectly well design, as also the green squares confirm them.

• On START BY LEFT UPPER CORNER:, You have there the PERFECT as EASIER WAY TO DESIGN/BUILD THE SPRING PIN From a Regular Bolt!! (GREAT!)
• BUT BELOW on "EXPLODED ASSEMBLY VIEW" >> [?1]
• >> [? 1]: You have a COMPLETELY different Approach of Spring Pin Design?  Why?

On the CENTER MIDDLE IMAGE, You have the BRUSH VIEWED BY BACK, SPRING ON LEFT:

As the SPRING END IS NOT ON REAR BRUSH DEAD CENTER?, like You and I agreed before...
I have pointed out, with TWO RED LINES and a GREEN DOT ON REAR CENTER OF BRUSH BACK FACE.
Then, Your Spring is ABOVE ON LEFT Brush Quadrant, COMPLETELY OFF CENTER?

On the RIGHT of the OFF CENTER SPRING :

Is another view that You Titled "Assembled FRONT VIEW (Center Alignment"
That Image is WRONG!!

When You look at the Brush Assembly FROM THE FRONT VIEW You MUST HAVE THE IMAGE SHOWN BELOW:


NOW, RELATED TO BRUSH HOUSINGS:

On the GREEN SQUARES ON RIGHT, You have the PERFECT AND SIMPLER, EASIER WAY TO BUILD BRUSH HOUSING:

• You have CORRECTLY Specified the UPPER HOUSING.
• Which ONLY HAVE 4 BENDING LINES.
• PLUS, the Lower Brush Housing which is:
• Simply a FLAT PLATE, with TWO(2) Holes...

BUT THEN ON ? 2 & ? 3 (BOTTOM LEFT IMAGES):

• You are showing COMPLETELY DIFFERENT BRUSH HOUSINGS?
• Look like CASTING Aluminum?
• And MORE COMPLEX.
• MUCH DIFFERENT than your previous shown images on brush housing?

WHY ALL these HUGE Discrepancies within the SAME IMAGE that shows the Right Concepts, to then show different designs?

All these errors are very CONFUSING, for anyone reading or interpreting these Diagrams.

IF WE HAVE A VERY SIMPLE WAY TO BUILD SOMETHING, ANYTHING...

• WHY Complicate itwith a CLEVER DESIGN??
• WHY make it DIFFERENT from Original Right AND Simplest Designs?

Your Previous Diagrams Pages, also have same errors...BUT, I have just Pointed them out on Your LATEST RENDERING.

As You can realize, ALL GREEN AREAS ARE A HIGHER PORCENTAGE YOU GOT THEM ALL RIGHT.
RED ONES are just a MINIMAL PERCENT to Correct.

Regards dear friend!!

Ufopolitics

Reply to Message # 858

Hello dear friend Ufopolitics,

Thank you very much for taking the time to review the latest rendering so carefully and for marking the corrections.

You are completely right.
The green areas are the correct concept and should remain as the master reference. 

The red-marked areas introduced different geometry, especially in the exploded assembly view and brush housing details, and that makes the drawing confusing.

The next revision should follow only the simple original design:
• Spring pin made from a regular bolt
• Turned smooth upper spring area
• Slotted top for the spring lock end
• Threaded lower section for nut adjustment
• Simple upper brass housing with four bend lines
• Lower brass housing as a flat plate with two holes
• Carbon brush located between both brass plates
• Rounded V-shaped spring push end
• V push end resting exactly on the dead center of the rear brush face
• No cast-looking or more complicated housing parts
I also understand your point about the front view.

The correct front view must match your reference image, with the brush centered and the spring force aligned exactly with the rear centerline of the brush.

I will revise the rendering accordingly and remove the inconsistent parts so the complete drawing shows only one unified, simple, builder-friendly design.

Thanks again for the detailed correction. 
This helps keep the documentation accurate and easy for everyone to build from.

Regards, Alex (kampen)