SECTION 2 -BRUSH DESIGN, MANUFACTURE AND APPLICATION
Question 2:2 What Information Is Needed By A Brush Manufacture To Make a Brush?
Generally it is a matter of adequately describing the existing brushes if they are performing well provided no other changes are required.
Alternatively a sample can be supplied, though if it is worn then you will have to give the length required for the new brushes. If this is not known then look at a worn brush in the brush holder and pull the brush away from the commutator as far as possible, ensuring the spring remains comfortably positioned on the top of the brush.
Take a measurement from the top of the brush to the commutator for the new maximum length.
To assist in providing all relevant details data sheets which indicate the required information are available from most brush suppliers.
These will generally supply sufficient information to manufacture the most common brushes.
The dimension are the most critical pieces of information.
The IEC136 standards have defined certain standards for nominal dimensions and the appropriate tolerances.
Note how close some of the dimension can be. Many problems have been introduced by, for example, identifying a brush as 16mm x 32mm when the holder was in fact a 5/8" x 1 1/4".
It is very important to determine if the brush is metric or imperial measurements. If there is any doubt the country of manufacture will usually given an indication.
American motors and older English motors are usually imperial while European and Japanese motors have generally been metric.
Most European suppliers manufacture brush holders with built-in clearance to current IEC standards, which specify a clearance above the nominal brush size.
Other holders may have no clearance or different clearances and brushes should be made to suit them.
Caliper holders need only to clamp or bolt firmly the carbon block and therefore require no special clearances.
The grades is very important. If the existing grade is not known then the nameplate information, along with any operating condition such as running current, needs to be supplied to the brush manufacture.
Take dimension of the lead and consider any changes that may be desirable.
Question 2:3 How Do You Select The Right Grade?
The information has been drawn from experience of Morganite Taiwan Limited Application Specialists combined with a wide range of published information from major carbon supplier and motor manufacture. However, the material can not be downloaded, copied or used without written permission.
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