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碳刷使用的問題及解答

 Answer To Questions on Carbon Brushes

了解碳刷的應用產品, 常常被比喻成一門藝術,而非絕對的科學.

然而,經由以下的問答與討論, 我們可以獲得足夠的基本知識. 

尤其從事迴轉機械的保養與維修的人, 可以應用這些基本知識, 與碳刷製造者通力合作, 藉以達到在設備上最佳的電刷使用績效. 

因為多數問題通常都從碳刷先顯現出來. 所以挑戰在於判斷問題究竟是來自於碳刷本身,或者碳刷只是反映機器設備的環境條件, 已經超過正常碳刷的操作能力範圍.  

這篇文章的目的, 在於充分的了解碳刷的使用績效,同時以較廣泛的觀點來觀察相關機器設備及操作環境, 進而認知可能或已經產生的碳刷績效不良的問題, 採取適當的調整行動. 

以下是目前最常被問到的問題, 提供的解答有可能未竟完善, 然而, 若需要進一步的資料或解答, 可接洽我們的工程師. 

The understanding and application of carbon brushes is often said to be more an art than an absolute science.

Nevertheless, by discussing questions that have been asked by those involved with the subject we can gain an adequate basic understanding.

In particular, people involved in the maintenance and repair of rotating machines can apply the basic knowledge and work along with the carbon brush manufacture to get the very best performance from brushes and associated equipment.

Brushes are often the place where problems show up first. The challenge is to determine if there is in fact a brush problem or whether the brushes are simply reacting to some machine fault or other circumstance which is outside the normal capability of the brushes.

The objective of this information is to understand brush performance sufficiently to look at the wider picture of associated equipment including environment and to recognize existing or developing unfavourable brush performance and take the appropriate corrective action.

These are currently the most common questions that have been addressed and the comments given may not cover all possible aspects of the question, however, additional information is available upon request.

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.

以上資訊為台灣摩根先進材料股份有限公司應用工程專家提出, 未經書面許可請勿下載複製及引用

Q & A INDEX

第一部分 - 介紹碳刷及碳刷材質

SECTION 1  -INTRODUCTION TO BRUSHES AND CARBON GRADES

問題 1:1 為什麼叫做碳刷?

Question 1:1 Why Are They Called "Brushes"?

問題 1:2 為什麼要用碳刷?

Question 1:2 Why Is Carbon Used?

問題 1:3 碳刷是什麼材料製成的?

Question 1:3 How Is The Carbon Brush Material Made?

問題 1:4 加了什麼添加劑?

Question 1:4 What Additives Are Used?

問題 1:5 為什麼有些碳刷看起來像銅?

Question 1:5 Why Do Some Brushes Look Like Copper?

問題 1:6 有多少種碳刷材質?

Question 1:6 How Many Brushes Grades Are There?

問題 1:7 通常碳刷材質都是哪些範圍?

Question 1:7 What General Groups Do Brush Grades Fall Into?

問題 1:8 滑環與整流子碳刷是不同的嗎?

Question 1:8 Are Slipring And Commutator Brushes Different?

問題 1:9 材質選用有通用的標準嗎?

Question 1:9 Are There Any General Principles For Grade Selection?

問題 1:10 碳刷是否有標準?

Question 1:10 Are There Any Standards For Brushes?

問題 1:11 碳刷是否有保存期限?

Question 1:11 Do Brushes Have a Shelf Life?

問題 1:12 已安裝碳刷的備用馬達該如何儲存?

Question 1:12 How Should A Spare Motor, Fitted With Brushes, Be Stored?

問題 1:13 針對碳材料而言, 有哪些安全上適當的顧慮?

Question 1:13 What Safety Considerations Are Appropriate For Carbon?

第二部分 - 碳刷設計,生產與應用產品

SECTION 2  -BRUSH DESIGN, MANUFACTURE AND APPLICATION

問題 2:1 碳刷如何生產?

Question 2:1 How Are Carbon Brushes Made?

問題 2:2 碳刷製造者需要哪些資訊來製作碳刷?

Question 2:2 What Information Is Needed By A Brush Manufacture To Make a Brush?

問題 2:3 如何選擇正確的材質?

Question 2:3 How Do You Select The Right Grade?

問題 2:4 為什麼碳刷頂端或底部有角度?

Question 2:4 Why Do Brushes Have Top Or Bottom Angles?

問題 2:5 為什麼碳刷要分片?

Question 2:5 Why Are Brush Split?

問題 2:6 是不是分片碳刷的兩片材質一定一樣?

Question 2:6 Are Split Brushes Always The Same Grade in Both Pieces?

問題 2:7 碳刷頂端的橡膠/纖維墊片的目的是什麼?

Question 2:7 What Is The Purpose Of The Rubber/Fibre Pad On The Top?

問題 2:8 為什麼有些碳刷表面有一個安裝差梢?

Question 2:8 Why Do Some Brushes Have An Insert Fitted In The Face?

問題 2:9 為什麼有些碳刷表面有切割?

Question 2:9 Why Do Some Brushes Have Saw Cuts In The Face?

問題 2:10 為什麼有些碳刷側面或內面有溝槽?

Question 2:10 Why Do Some Brushes Have Grooves In The Side Or Internal Faces?

問題 2:11 活動接線的尺寸和數量如何決定?

Question 2:11 How Is The Flexible Connection Lead Size And Number Determined?

問題 2:12 有沒有警告儀器可以偵測碳刷短路?

Question 2:12 Are There Any Warning Devices To Indicate Short Brushes?

第三部分 - 碳刷理論與特性 

SECTION 3 - BRUSH THEORY AND CHARACTERISTICS

問題 3:1 什麼是"整流"?

Question 3:1 What is "Commutation"?

問題 3:2 電阻是指碳刷裡的哪一部分?

Question 3:2 What Part Does Resistivity Play In A Brush?

問題 3:3 什麼是接觸點或電壓點?

Question 3:3 What Is Contact Drop Or Voltage Drop?

問題 3:4 碳刷適中的硬度是多少?

Question 3:4 What Relevance Is Brush Hardness?

問題 3:5 什麼是電流密度?

Question 3:5 What Is Current Density?

問題 3:6 電流密度如何計算?

Question 3:6 How Is Current Density Calculated? 

問題 3:7 低電流密度如何做?

Question 3:7 What Can Be Done About Low Current Density?

問題 3:8 什麼導致碳刷磨耗?

Question 3:8 What Cause A Brush to Wear Out?

問題 3:9 什麼是機械磨耗?

Question 3:9 What Is Mechanical Wear?

問題 3:10 什麼是電氣磨耗?

Question 3:10 What Is Electrical Wear?

問題 3:11 什麼是碳刷正常的壽命?

Question 3:11 What Is Reasonable Brush Life?

問題 3:12 什麼形成整流或滑環皮膜?

Question 3:12 What Cause The Commutator Or Slipring Patina?

問題 3:13 讓馬達在沒有負載的情況下運轉好不好?

Question 3:13 Is It Good To Let A Motor Run On No Load?

問題 3:14 什麼是"黑帶"測試?

Question 3:14 What Is "Black Band" Test?

問題 3:15 SCR驅動有給碳刷帶來問題嗎?

Question 3:15 Do SCR Drives Cause Problems For Brushes?

問題 3:16 為什麼有些滑環和整流子有螺旋溝槽?

Question 3:16 Why Do Some Sliprings And Commutators Have Spiral Grooves?

問題 3:17 什麼是"S冷卻係數"?

Question 3:17 What Is The "S Cooling Factor"?

第四部份 - 碳刷架設計,維修與調整

SECTION 4 - BRUSH HOLDER DESIGN, MAINTENANCE AND ADJUSTMENTS

問題 4:1 碳刷架有哪些型式?

Question 4: 1 What types Of Brush Holders Are There?

問題 4:2 可以改變碳刷架型式嗎?

Question 4:2 Can Brush Holders Changed To Another Type?  

問題 4:3 甚麼是"Tensator"彈簧?

Question 4:3 What are “Tensator” Springs?

問題 4:4 可以檢查碳刷架的哪裡?

Question 4:4 What Checks Can Be Made On Brush Holders?  

問題 4:5 碳刷架內的碳刷空隙應有多少?

Question 4:5 How Much Clearance Should A Brush Have In The Holder?

問題 4:6 正確的彈簧壓力是多少?

Question 4:6 What Is The Correct Spring Force?  

問題 4:7 彈簧壓力如何測量調整?

Question 4:7 How is Spring Force Measured And Adjusted?

問題 4:8 頂端的角度是否影響彈簧設定?

Question 4:8 Does A Top Angle Affect Spring Setting?

問題 4:9 底部的角度是否影響彈簧設定?

Question 4:9 Does A Bottom Angle Affect Spring Settings?

問題 4:10 碳刷握的位置及空間有多重要?

Question 4:10 How Important Is Brush Holder Position And Spacing?

問題 4:11 什麼是軸向差排?

Question 4:11 What Is Axial Stagger?  

問題 4:12 什麼是圓週差排?

Question 4:12 What Is Circumferential Stagger?

問題 4:13 什麼是中性點?

Question 4:13 What Is The Neutral Position?

問題 4:14 要如何找中性點?

Question 4:14 How Do You Find Neutral?

問題 4:15 是不是所有的機器在中性點操作狀態都最佳?

Question 4:15 Do All Machines Run Best At Neutral Position?

問題 4:16 什麼是電場衰減?

Question 4:16 What Is Field Weakening ?

第五部分 - 碳刷保養與機器修護

SECTION 5 - BRUSH MAINTENANCE AND MACHINE CARE

問題 5:1什麼是正確的保養?

Question 5: 1 What Is Correct Maintenance?

問題 5:2 建議日常保養與檢查所需要的工具是什麼?

Question 5:2 What Tools Are Suggested For Routine Maintenance And Investigations?

問題 5:3 透明的檢查蓋有什麼優點?

Question 5:3 What Are Benefits Of Clear Inspection Covers?

問題 5:4 碳刷及整流子檢查的重點為何?

Question 5:4 What Guidelines Are There For Brush And Commutator Inspection?

問題 5:5 碳刷在什麼長度時應該更換?

Question 5:5 At What Length Should Brush Be Replaced?

問題 5:6 需要將碳刷著床嗎?

Question 5:6 Do You Need To Bed Brush In?

問題 5:7 碳刷如何著床

Question 5:7 How Are Brushed Bedded In?

問題 5:8  變更材質後該如何?

Question 5:8 What Should Be Done If Changing Grades?

問題 5:9 如果材質混合會如何?

Question 5:9 What Happen If Grade Are Mixed?

問題 5:10 整流子及滑環可以在機器上研磨嗎?

Question 5:10 Can Commutators And Sliprings Be Ground In The Machine? 

問題 5:11 整流子何時應該被轉動?如何做?

Question 5:11 When And How Should Commutators Be Turned? 

問題 5:12 向下切割是否是必須的?

Question 5:12 Is Undercutting Necessary?

問題 5:13 什麼是正確的向下切割?

Question 5:13 What Is Correct Undercut? 

問題 5:14 油如何影響整流子與碳刷?

Question 5:14 How Does Oil Affect Commutators And Brushes?

問題 5:15碳刷可以在溶劑裡清洗嗎?

Question 5:15 Can Brushes Be Washed In Solvent?  

問題 5:16 什麼空氣雜質會影響碳刷?

Question 5:16 What Atmospheric Contaminants Affect Brushes?

問題 5:17假如是振動的機器會如何?

Question 5:17 What Happens If The Machine Is Subject To Vibration?

第六部份 - 一些常見的操作問題

SECTION 6 - SOME COMMON OPERATING PROBLEMS

問題6:1 為什麼電線露到碳刷外?

Question 6:1 Why Do Leads Fall Out Of Brushes?

問題6:2 什麼造成整流子溝槽及貫穿?

Question 6:2 What Causes Commutator Grooving And Threading?  

問題6:3 為什麼整流子有平坦點?

Question 6:3 Why Do Commutators Get Flat Spots?  

問題6:4 什麼導致碳刷有時候擠在碳刷架內?

Question 6:4 What Causes Brushes To Sometimes Jam In Holders?  

問題6:5 為什麼有些碳刷在相同的機器上磨耗不同?

Question 6:5 Why Do Brushes Wear Sometimes Differently In the Same Machine?

問題6:6 為什麼再安裝的碳刷磨耗比原裝的碳刷磨耗多?

Question 6:6 Why Do Replacement Brushes Sometimes Appear To Wear More Than The Original Set?  

問題6:7 為什麼有些碳刷有銅線過熱或曲線損壞,但其他的看起來正常?

Question 6:7 Why Do Some Brushes Sometimes Have Overheated Leads And Arcing Damage While Others Appear Normal?

問題6:8 什麼構成碳刷額外的磨耗和灰塵?

Question 6:8 What Causes Brushes To Wear And Dust Excessively?  

問題6:9 為什麼有些碳刷在側面磨耗特別嚴重?

Question 6:9 Why Do Some Brushes Show Signs Of Excessive Wear On The Sides?  

問題6:10 為什麼有些整流子顯現規律的黑白分區?

Question 6:10 Why Do Some Commutators Show Regular Light And Dark Patterns On The Segments? 

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.

以上資訊為台灣摩根先進材料股份有限公司應用工程專家提出, 未經書面許可請勿下載複製及引用