An alternator includes an external ignition protection system including a shaft rotatable about an axis. The shaft includes a slip ring end. A slip ring support is mounted at the slip ring end of the shaft. A slip ring cover is mounted to the shaft. The slip ring cover defines a slip ring cavity. A first slip ring end housing supports the slip ring cover. The first slip ring end housing includes a first plurality of openings. A second slip ring end housing is arranged axially outwardly of the slip ring end. The second slip ring end housing includes a second plurality of openings. The first slip ring end housing, slip ring cover and the second slip ring end housing define a labyrinth flow path that provides an air flow through the slip ring cavity and prevents passage of ignition inducing elements from the alternator.

A brush lead guide for a brush holder assembly configured to retain the leads extending from a brush in a desired position/orientation to ensure the leads do not interfere with movement of the brush within the brush holder. In some instances, the lead guide includes a first guide rail including a channel for receiving a first lead of the brush and a second guide rail including a channel for receiving a second lead from the brush. The lead guide maintains the leads in a position such that the leads are held within the width of the opening of the brush holder to ensure the leads do not interfere with movement of the brush within the brush holder during use of the brush holder assembly.

A brush lead guide for a brush holder assembly configured to retain the leads extending from a brush in a desired position/orientation to ensure the leads do not interfere with movement of the brush within the brush holder. In some instances, the lead guide includes a first guide rail including a channel for receiving a first lead of the brush and a second guide rail including a channel for receiving a second lead from the brush. The lead guide maintains the leads in a position such that the leads are held within the width of the opening of the brush holder to ensure the leads do not interfere with movement of the brush within the brush holder during use of the brush holder assembly.

There is provided a motor, the motor comprising (1) a brush unit that is provided at one axial direction side of a motor main body, and that includes a first brush and a second brush, (2) a pair of power supply terminals that are provided at the brush unit, that are respectively electrically connected to either the first brush or the second brush, and that include connector connection portions to which external connectors connect and that extend out toward another axial direction side of the motor main body at respective other end sides of the power supply terminals, and (3) a pair of element connection portions that are respectively provided at the other end sides of the power supply terminals, and that are disposed offset from each other in the radial direction of the motor main body.

There is provided a motor, the motor comprising (1) a brush unit that is provided at one axial direction side of a motor main body, and that includes a first brush and a second brush, (2) a pair of power supply terminals that are provided at the brush unit, that are respectively electrically connected to either the first brush or the second brush, and that include connector connection portions to which external connectors connect and that extend out toward another axial direction side of the motor main body at respective other end sides of the power supply terminals, and (3) a pair of element connection portions that are respectively provided at the other end sides of the power supply terminals, and that are disposed offset from each other in the radial direction of the motor main body.

A brush plate has an insulating substrate, at least one pair of brushes mounted on the insulating substrate, and a conductor for supplying power to the brushes. The conductor includes at least one overheat protection portion having a smaller cross sectional area than adjacent portions of the conductor. By integrally forming the overheat protection portions on the conductors, no extra overheat protection device is required. Preferably, the overheat protection portion has a bent structure. The bent structure may be U-shape, Z-shape, M-shape or wave-shape. The bent structure can increase the anti-shock capability of the conductor and shorten the response time of the overheat protection portion.

A brush plate has an insulating substrate, at least one pair of brushes mounted on the insulating substrate, and a conductor for supplying power to the brushes. The conductor includes at least one overheat protection portion having a smaller cross sectional area than adjacent portions of the conductor. By integrally forming the overheat protection portions on the conductors, no extra overheat protection device is required. Preferably, the overheat protection portion has a bent structure. The bent structure may be U-shape, Z-shape, M-shape or wave-shape. The bent structure can increase the anti-shock capability of the conductor and shorten the response time of the overheat protection portion.

An electrical connector includes a body having a bore and an interior surface. The bore is sized to receive a cable conductor of an electrical power cable. The body includes a groove disposed along a length of the interior surface. A wire brush insert is located within the groove and includes a plurality of bristles that extend into at least a portion of the bore. Rotating the cable wire brushing connector relative to the cable conductor cleans the cable conductor prior to securing the cable conductor within the cable wire brushing connector.

An electrical connector includes a body having a bore and an interior surface. The bore is sized to receive a cable conductor of an electrical power cable. The body includes a groove disposed along a length of the interior surface. A wire brush insert is located within the groove and includes a plurality of bristles that extend into at least a portion of the bore. Rotating the cable wire brushing connector relative to the cable conductor cleans the cable conductor prior to securing the cable conductor within the cable wire brushing connector.

An opening of a yoke provided to an electric motor is closed by a brush holder of an electricity supply unit. A pair of electricity supply terminals connected to respective brushes is fixed on the brush holder by outsert molding. A brush-side fixing pillar is inserted into a caulking hole piercing through a pigtail connecting portion of each electricity supply terminal, an input-side fixing pillar is inserted into a fixing hole piercing through an input-side connecting portion, and then the brush-side fixing pillar and the input-side fixing pillar are thermally caulked, whereby each electricity supply terminal is fixed on the brush holder. Each input-side fixing pillar and the corresponding brush-side fixing pillar, provided on the brush holder, are spaced away from each other by a predetermined distance so that a first terminal, a second terminal and a choke coil connected therebetween is attachable in place of the electricity supply terminal.