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Schunk Kohlenstofftechnik
SKT / GB4 Page: Frequently asked questions
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Frequently asked questions
Content General Brush manufacturing, design and application Theory Brush holders Maintenance Common problems
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1. General
9. Are any safety measures necessary while cleaning motors? 8. Is there any shelf live for carbon brushes ? 7 .General principle for grade selection ? 6. Are slip ring and commutator brushes different ? 5. What general groups of brush grades do exist ? 4. What additives are used ? 3. How is carbon made ? 2. Why carbon ? 1. Why are they called brushes ? SKT / GB4 Page:
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4. How may I select the right grade ? 3. Which information is needed for a brush supplier ? 2. Which connections cable / brush do exist ? 1. How are brushes made ? SKT / GB4 Page:
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14. What is field weakening ? 2. What role does resistivity play in a brush ? 13. Why do some slip rings have spiral grooves ? 1. What is commutation ? SKT / GB4 Page:
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4. Brush holders
10. How much clearance should a brush have ina holder ? 9. What is circumferential staggering ? 8. What is axial staggering ? 7, How important is brush holder spacing ? 6. Are there any standards for brush holders ? 5. How is the spring force measured and adjusted? 4. What is the correct spring force ? 3. Do brush holders have a corrosion protection ? 2. What is the pressure curve of a brush holder ? 1. What types of brush holders are there ? SKT / GB4 Page:
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5. Maintenance
8. How can I set the neutral position ? 12. How does oil influence commutators and brushes ? 11. Is undercutting necessary ? 10. When and how should commutators be turned ? 9. Can commutators and slip-rings be ground in the machine ? 7. What happens if grades are mixed ? 18. Why is surface roughness so important ? 6. What should be done if changing grades ? 17. What has to be done if the motor has to stored for a long period ? 5. How are brushes bedded in ? 16. How to measure collector temperature ? 4. Do I need to bed brushes in ? 15. What happens if the machine is subject to vibration ? 3. At what length should a brush be replaced ? 14. What atmosphere contaminants affect brushes ? 2. What are suitable parameters to indicate motor performance ? 13. Can brushes be washed in solvent ? 1. Which regular machine checks should be done ? SKT / GB4 Page:
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6. Common problems
10. What causes selective action ? 9. What causes differential wear of slip rings ? 8. Why do some commutators show regular light and dark patterns on the segments ? 7. What causes brushes to wear and dust excessively ? 6. Why do some brushes sometimes have overheated flexibles ? 5. Why do brushes sometimes wear differently in the same machine ? 4. What causes brushes to get stuck in the holder ? 3. Why do commutators get flat spots ? 12. What are reasons for copper drag ? 2. What causes commutator grooving and threading ? 11. What is out-of-roundness ? 1. Why do shunts fall out of brushes ? SKT / GB4 Page:
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Chapter 1 General
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The term "Brush" correctly described the item they used but because it had high friction and wear it wasn't long before the bristle brush was replaced and carbon blocks were used as a much better alternative.
The name "Brush" however has remained to the present days Approx.1870 copper brushes 1885 first patent for carbon for sliding contacts
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Carbon has some unique properties which makes it the preferable material for electrical sliding contacts Good electrical and thermal conductivity Low shear strength of graphite crystal Low friction coefficient Low modulus of elasticity Retains moderate strength at high temperature No melting point, passing from solid to vapour at 3500C No welding between carbon and counter material Wide band of phys. Characteristics by means of - Raw materials - Process - Design
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case of electro-graphite grades a further process of passing electric current through the blocks or by inductive methods changes the crystalline structure of the material. In the first case the process is called electro graphitisation or Acheson-graphiti-sation. The porous structure of the materials enables various aftertreatments to modify the materials properties.
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additives can improve the performance and brush life under certain circumstances.
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Depending on the raw material used, this group contains a greater or lesser proportion of very finely distributed inorganic impurities, which give the natural graphite a certain abrasive property as well as good frictional performance. On the one hand, this makes the material suitable for operation on steel rings at high running speeds, while on the other, it can be used in the form of so-calIed cleaning brushes as supplementary equipment, for example to remove slight burn marks or to counteract excessive film formation. Because of the particular structure of natural graphite, the material feels extremely soft and smooth. Natural graphite brushes can be loaded continuously up to 10 A/cm, but will also withstand short-time current peaks up to 20 A/cm
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Carbon bearings with white metal, antimony and other impregnations are used in mechanical applications.
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Throughtheresin bonding,however,theleadcapacityand especiallytheoverloadcapacityisstill lowincomparisonwithelectrographitebrushes. Specificcontinuouscurrent currentdensitiesof8 -10A/cm(51current 64A/in)shouldnotbe exceededforlongperiods.OnD.C D.C.machines, D.C short-termpeakvaluesupto12A/cm (77A/in)arepermissible.
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Low resistance electrographite brushes can be used for lower currents and metal graphite grades (metal content up to 90% metal) are used for higher currents. Brushes with 50%-75% metal content are the most common brushes used on slip-rings of induction machines.
The construction of a slip ring brush will usually a solid block brush with the cable number and size to carry the relatively high currents.
Commutator brushes generally have their widest dimension axially along the length of the commutator segments with the number of brushes per arm according to the required current and type of carbon used.
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Commutator brushes can be of the copper graphite type for less than 48 volt DC supply because of the high current involved. However, by far the bulk of commutator brushes will be made of electrographite with medium to high resistance depending on the load, the application and machine design. The construction of commutator brushes can be varied from a block brush to the most complex multi-wafer type with grades and other features from a large range of possibilities.
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1. Slip rings
Low resistance electrographite grades are used for current density less than 10A/cm (65 A/in) and effective cooling conditions. Grades from the metal graphite class with 50%-75% metal are used for current densities up to 15A/cm (97A/in). Very high current welding jigs etc. require metal graphite up to 90% metal.
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with a percentage of 25%-75% metal. Generally the higher the voltage, the less metal percentage is required depending on the brush configuration.
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Metal graphite brushes or the cooper flexible connection may be subject to corrosion if stored in an unsuitable atmosphere. If corrosion is present, a possibility may be to order brushes with tinned shunts which will assist in
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Persons with existing respiratory conditions may experience irritation from breathing high concentrations of dust.
The material safety data sheets (MSDS) are available for full details.
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1 Tamped Connections
The tamped connection is mechanically strong and of low electrical resistivity. A copper wire is placed in a hole and fine powder is compacted around the flexible with special machines, which guarantee a virtually solid bond between the brush body and the copper lead. The top of the tamped connection is sealed to prevent corrosion. This is the preferred and most effective method of wire connection for normal applications.
2 Riveted Connections
This type of connection is also widely used. It is mainly applicable when brush proportions are not suitable for the tamped version or for soft carbon grades. The flexible lead is looped around a copper rivet fitted into a prepared recess and the rivet flared over to hold pressure between the wire and the carbon surface. The same rivet can be used to secure a metal top when fitted. However, this dual use of the rivet is not recommended.
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manufacturer need the following data: OEM of the motor motor - Power kW/HP - Voltage V - Nominal current A - Actual current A - Peripheral speed m/s - Number of Poles - Brushes / Pole - Brush dimensions Application
In case of problems additional information is necessary. Description of the problem Present brush grade Actual number of brushes
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service received from customers and from field engineers in all parts of the world. Results from the laboratories of the brush suppliers support grade selection. In order to make the right choice some basic information like OEM of the machine, application, actual load data and grade presently in use are helpful (see here) Grade selection is always a compromise, since there are no super grades existing. Different parameters, sometimes mutually contradictory, have to be taken into consideration. Some trials, patience and time can be required to find the best grade for a particular application.
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It collects and expels dust to the side. The cut interrupts the air cushion in the contact face, which develops at high speeds and might lift individual brushes from the collector. Thus the cut avoids the so called aero-planning of brushes and guarantees more uniform current distribution.
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2.8. Why do some brushes have grooves in the side or internal face ?
These are grooves which minimize the risk of carbon dust building up on the brush faces which can result in the brush sticking in the holder. The grooves tend to clear the dust assisted by air movement through the grooves. Dust grooves are most commonly applied to slip ring brushes where the copper dust is more prone to building up inside the holders.
DC motor brushes can also have grooves on the outside or inside faces. Low voltage forklift motor and traction motor brushes often have diagonal grooves across the outer faces.
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The length of the shunt is measured from the top of the brush to the centre of the terminal. The cable must be long enough to allow full travel of the brush to its shortest position in the brush holder. If the cables are excessively long there is the possibility that they could foul in rotating parts, particularly in the case of Schrage type motors where the leads could catch in the moving gears. Another problem with long flexibles can be that in motors with high velocity cooling air the turbulence may cause some leads to move excessively and to get damaged by this movement.
Placing a plastic band or a metal clip approximately midway along the length provides additional support. In some traction applications the copper wired can incorporate some steel strands to strengthen it.
If the flexibles are relatively small in diameter placing a single insulation over two leads also gives additional support and keeps the leads tidy.
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The cable diameter is generally selected in relation to the maximum current that the particular brush can handle considering its dimension and the type of material used. For high current carrying metal graphite brushes the cables would be much larger than for an electrographite brush of the same dimension.
Another consideration of the shunt diameter is potential short term overload. The brush material can stand overload to varying degrees, however the lead may be the limiting factor, particularly with high starting currents that can occur with, for example, traction motors or electric forklift motors. In these cases the shunt is best dimensioned to the largest cable practical to fit in the brush, taking into consideration how the flexibility of the lead my affect the free movement of the brush up and down in the brush holder.
3 Flexible Insulation
Though wire insulation prevents the cable shorting to earth or other live components nearby, it is better not to fit it as a standard option, if it is not necessary. This is because it adds to the cost and decreases the radiation and dissipation of heat arising in the shunt.
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Detectors can also be embedded within each brush which, combined with appropriate external circuits, can positively indicate brushes of critical length. If every brush has to be monitored the amount of cables in the machine is a major disadvantage of this method.
Adequate short circuit protection must be used where these indicating circuits are directly connected to the brush holders as armature voltages and high prospective fault currents are present.
Power tool brushes can have lift-off devices fitted into the brush which consist of a spring loaded pin which releases when the brush wears to the predetermined position.
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Chapter 3 Theory
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0 + IA - IA is 0 Switching-off Switching-on
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loss arising from this resistance of the brush material is only 10% of that which is dissipated at the brush contact surface due to contact-resistance and friction. Contactresistance,coefficient offrictionandthermalconductivityof thebrushhaveamuchgreaterinfluence thantheresistivityofthematerial. Themeasurementof resistivityishoweverausefulquality controltestinproduction.
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brush and strip, This stability cannot be described with the macroscopic value hardness. The most impressive example is a "soft" carbon brush grade , which gives a much better performance e.g. on large mill or fast running machines than "hard" brush grades. Cleaning and polishing action is also not determined by the hardness of a material. The ingredients of the material do have a much bigger influence. Commutator attack is not triggered by "hard" materials, but by the ambient conditions, uneven current distribution or electrical overload. The same is valid for the catenary wear caused by carbon strips. The catenary wear is particularly triggered by abrasive mineral ingredients as impressively. Appropriate information can be given on request.
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terminal. The sum of al1 these resistances is cal1ed the contact resistance of a carbon sliding contact The voltage drop due to the contact resistance of two carbon brushes series-connected across a short circuited commutator or slip-ring is called the contact voltage. (In accordance with IEC Publication 276, voltage drop for two brushes in series) This is an important quantity for the user of carbon brushes since it inf1uences commutation and ohmic losses. The voltage drop is made up of the component voltage drops shown. The contact voltage drop U3 of an electrographite brush grade of average resistivity amounts to about 80 -85% of the tota1 voltage drop u. The percentage is still higher n the case of metal-carbon grades. It is therefore permissible to use the contact voltage as a measure of the contact conditions in the practical application and evaluation of the quality of a carbon brush ?U3 ?U ?U2
?U1
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is therefore determined by the maximum current density which occurs. If the coil resistance and the inductance of the commutation circuit are predominant in a machine, the influence of the voltage drop becomes rather less important. The factor of contact stability with high current densities, such as occur during commutation at the edges of the brushes, becomes more important. This is also the reason why relatively low-resistance materials without a particularly wide commutation band but with good contact stability ( coke-based materials) have better performance on large machines than high-resistance materials which are less capable of withstanding surge loadings (carbon-black based materials). Things are somewhat different, f the commutation is not only influenced as a result of inductances, hut additional induced voltages are present in the commutation circuit. This is more or less the case with D. C supplies with a relatively high C. harmonic content in the supply voltage. Here it sometimes becomes necessary to use high-resistance material, right up to resin-bonded graphite or even sandwich carbon brushes, with a high voltage drop in order to reduce the transverse currents caused by the induced vo1tages. If a machine shows mechanical difficu1ties, the commutation characteristic of a carbon brush as such can only be influenced to a slight degree, in order to improve the commutation, by the use of a different material. The greatest successes are obtained here by changing the design of the carbon brushes, e. g., with twin brushes etc.
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The actual current a brush can carry is widely influenced by operating conditions such as type of ventilation, continuous or intermittent duty, speed and other factors. The published data sheet ratings for electrographite brushes are generally conservative, some allowance having been made for short term overloads above those listed in the published data.
The current carrying capacity of a brush depends ultimately on the operating temperature. On well-ventilated machines having small brushes with larger surface area in proportion to their volume and where brushes cover only a small percentage of the commutator or ring surface, conventional current densities for electrographite grades can often be doubled without seriously jeopardising their performance.
On the other hand, increasing the current density without making provisions for maintaining a suitable low brush temperature may reduce the brush life dramatically. In practice low current density in a machine caused by running a machine below full rated load is potentially more damaging than a moderate overload. For good operating temperature and performance as a general rule, the actual operating current density should be not lower than 60% of the published rated current density.
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1000 A 6 pole 5 cbs each, i.e. 30 brushes, i.e. calculation with 15 brushes 20 x 32 x 50 mm 1000A - 4 pole 5 ea. Tandem Brushes , i.e. 20 brushes, calculation with 10 brushes 12,5 x 32 x 50mm Tandem Brushes i.e. total dimension - t is 25mm
DC DC Motors
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Turbogenerator 1000A - 2 rings with 10 cbs each , i.e. calculation with 10 brushes 32 x32 x64mm Asynchronous-Slip-Ring Drive 500A - 3 rings 5 cbs, i.e. calculation with 5 brushes 40 x 20 x 40 mm
Slip ringdrives
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3.8. What is the reason for low load problems and what are remedies ?
Carbon brush
Collector
Contact point
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The film consists of Graphite and copper oxides copper oxide is a semiconductor High el. resistance at low temperatures current goes via some frit bridges only
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3.8. What is the reason for low load problems and what are remedies ?
Mechanical breakage of copper particles out of the surface Hard copper particle in the contact surface
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grooving Carbon brush Collector Remedial action reduce number of brushes track wise use preheated cooling air reduce cooling air (ask OEM first) use a low load resistant brush grade
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Remedial measures are Filter the cooling air Supply cooling air from alternative (clean) source Change cooling air flow direction Use brushes with dust grooves
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regarded as being in the region of 0.2 to 0.35 mm per km. 1000 km Uneven brush wear should only be objected to if there are large differences in length after a long running time. Smaller differences in length, e. g. 10 % should be considered as normal. .
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Brush wear depends mainly on the distance the brush travels on the collector. An empirical formula for industrial application is:
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CarbonBrushFace Chartsindicategoodcommutatorconditions howeverinpracticemanycommutatorshave operatedformanyyearswithaless thanidealappearance.Providedthebrush andcommutatorwear weariswithinnormallimits wear thenactiontotryandachievethe idealappearancemaybepointless.
Water Brush
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differential brush wear which could lead to burned shunts etc. wear,
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below. Motor Field Current 4.2 / 2.5 amps Motor Rated Speed 1750 / 2100 RPM The motor will deliver full Torque and Horsepower only at Full Field, Full Armature Voltage and Full Armature amps.
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the brush and the commutator. The commutator then can burn and pit and brush life is reduced. It is thus necessary to insure that voltage is not induced in the commutator loop at the time of the momentary short. If the short occurs when the active conductors in the armature loop are moving in parallel to the field, magnetic lines of force will not be cut and voltage will not be induced in the armature loop. This vertical axis occupied by the shorted armature loop is the geometric neutral axis In theory, this is where axis. black commutation takes place. But life is not that simple! Due to the self induced e.m.f. and changes in load, the situation is somewhat more involved and beyond the scope of this article. In the end however, electrical neutral must be properly set to assure good commutation and good brush life.
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Aftercleanedwindings havebeendried,itisimportantto remember that the insulation resistance is lower when the winding is warm. Insulation resistance can be accurately measured only when the winding is allowed to cool down to room temperature (approximately 20 to 30 C). Measuringvoltage:500 V(atleast100V)ata windingtemperatureof25CThe minimuminsulationresistanceofnew,cleaned orrepairedwindingsmustbe>10 M. .
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according to the circuit and the operating conditions, in the D.C voltage. D.C. There are also high rates of rise of current and surge stresses, which only occur occasionally during control or regulation processes. Harmonics in the D.C voltage and eddy currents in the magnetic circuits D.C. make current reversal difficult. These increased stresses are counteracted by appropriate motor design ( e. g. lamination of the magnetic circuit etc.). With a high ripple or even discontinuous operation (in sma1l motors on simple equipments), however, considerable residual voltages still remain and must be dealt with by the carbon brushes. For this purpose, high-resistance carbon brush materials (including sandwich brushes) or even resin-bonded materials are used for preference. High surge stresses are more likely to occur with large machines. With such a surge load, in many cases a phase shift occurs between the commutating field and the armature field, resulting in severe sparking at the brushes. Since a steep rise in current is also often associated with a current overload, the commutation difficulties increase. Carbon brush materials which make good contact and are capable of withstanding surge loads are a suitable remedy. It is generally acknowledged that there is no universally applicable carbon brush for the field of D. C machines fed from controlled rectifiers. High resistance, medium C. resistance or low-resistance materials must be selected depending on the type of stresses.
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High ripple levels or discontinuous-current operation can cause continuous vibrations, resulting from magnetic forces. These have an unfavourable effect on the mechanical contact between the carbon brushes and the commutator. Electrical surge loadings also lead to mechanical stresses on the sliding contact of the carbon brushes, as a result of magnetic forces on the mechanica1 parts. With rapid changes of speed, the position of the carbon brushes in the holders can change, even to the extent of tilting during reversal. In all the cases mentioned above, the contact between the carbon brushes and the commutator can be improved if, for example, and provided the brush dimensions permit, split brushes are used rubber pads are provided on the brush head or the brush pressure is somewhat increased.
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the surface of the rotor. This is best achieved by means of a rubber or laminate plate laid or glued on to the top surface. Apart from giving uniform pressure distribution, the plate also ensures that the brush sections can move independently for a short distance in a radial direction which means that the carbon brush can contact the commutator independently from its ovality. Where a commutator is out of true, the fact that the brush is divided also results in lower acceleration respectively inertia forces, so that the contact points on the commutator are subject to lower mechanical stress. Twin and triple carbon brushes have a larger number of contact points between the running surface of the carbon brush and the commutator, with the result that the local current density compared to a block carbon brush is lowered. At the same time this is associated with an extension of the commutation time so that the current reversal stresses are reduced.
Block Brush Twin Brush Tripple Brush
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Split Brush
Split brush This type is a special form of the twin brush. Both brush wafers have their upper surface inclined towards the middle of the brush. The two brush sections are spread apart seen from the brush head side so that the clearance between the carbon brush and the brush box is reduced, or even closed up entirely. With machines susceptible to oscillation the increased friction between the carbon brush and the wall of the holder (damping) gives better contacting with the commutator.
Sandwich Brush Insulating layer
Sandwich brush Where commutation is difficult, so-called sandwich brushes may be used in order to avoid any difficulties that may arise, such as excessive sparking, scorching of the bars, heavy wear etc. Two wafers are bonded together by means of an insulating adhesive. As a result the cross resistance in the commutation circuit is increased, thus improving the commutation. The current supply to this kind of brush is normally arranged that every brush section has its own individual cable. With dual section brushes one of these is tamped into the area of the adhesive layer so that both carbon sections are contacted at the same time.
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Commutation is a quite often stressed word. The way it is used to describe the commutating capability of brush grades sometimes reads as though commutation is added to carbon material like pepper and salt to cooking. The course of the commutation process is mainly determined by the Following variables and properties: From the viewpoint of the machine: The inductance of the commutation coil Additional induced voltages in this coil The Ohmic resistance of this coil Concentricity and surface quality of the commutator and any vibrations of the brush holders
From the viewpoint of the carbon brushes The electrical contact resistance between the carbon brush and the segment The so-called energy capacity of the current-carrying contact points of the carbon material, i.e. the capability of the contact points to carry given current densities without thermal destruction, according to the material grade The mechanical running performance of the carbon brushes. Uneven running of the brushes decreases the commutation time and reduces the number of contact points.
The mechanical performance is determined by the friction coefficient, elasticity, mass and internal damping of the brush material.
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Flange brush holder Leg type holder Tubular holder Single brush holder
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Double clamp brush holder Plug in holder Tandem holder Brush rocker
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simple - durable - no joints - wear resistant - economically Pressure Characteristic constantly dropping pressure (variation about 20-30%)
Extension Spring
mostly used for industrial holders better vibration resistance than Constant Coil Spring Pressure Characteristic: usually crescent-shaped curve. (variation about 10-15%)
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usage of brushes with max. length Pressure Characteristic: almost same pressure over the entire brush length (variation about 5 - 10%)
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4.4. What is the correct spring force? All data in cN/cm Stationery commutator machines Data in cN/cm cN/cm (PSI)
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4.4. What is the correct spring force? cN/cm Slip ring drives Data in cN/cm (PSI)
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A large gap between brush holder and commutator is disadvantageous as there would be a high turning moment caused by the friction force pivoted on the bottom edge of the brush box and the brush is not guided properly by the brush box.
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covered systematically by the brush pairs of the following and preceding lines. On the other hand, in placing in the same track two brushes successively positive and negative, in order that each track may be covered by an equal number of brushes for each polarity, a frequent cause of apparition of stripes on the commutators is suppressed. This ordering of brushes on the commutator surface is called staggering or axial or lateral staggering. But this operation, easy to make, can be undertaken only on new commutators or renovated by the usual ways of grinding (lathe, grinding wheels, abrasive stone, etc)
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These two arrangements can be obtained by "all or nothing" as shown on b and c, or by progressive stagger as shown on d. By increasing in this way the number of bars covered by the brushes, the commutating time is increased and the speed of current reversal decreased in the commutated coil. The com-mutating difficulties of the machine are accordingly reduced.
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The effect of circumferential stagger is especially sensitive when: the number of commutator bars is great, the speed of the machine is high, the thickness of the brush is small ('t' dimension), i.e. the number of bars covered by a brush is smaller.
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20 16 0,072/ 0,232 -0,04/ -0,13 12,5 10 8 0,055/ 0,193 -0,03/ -0,11 6,3 5 0,050/0,178 -0,03/ -0,11 4 0,050/0,158 -0,03/ -0,09 3,2 2,5 0,044/ 0,144 -0,03/-0,09 2 Min/Max clearance on t and a dimensions Brush toleranceon t and a dimensions
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Nominal values
Metal freebrushgrades
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16 0,182/ 0,362 -0,15/ -0,26 12,5 10 8 0,105/ 0,253 -0,08/ -0,17 6,3 5 0,090/0,218 -0,07/ -0,15 4 0,090/0,218 -0,07/ -0,15 3,2 2,5 0,074/0,174 -0,06/-0,12 2 Min/Max clearance on t and a dimensions Brush toleranceon t and a dimensions
Nominal values
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Metal brushgrades
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By means of a location spot traced on the shaft of the machine check that the rotor does not stop in a preferential position As soon as the machine stops, measure by any appropriate means the temperature of the commutator and/or each of the rings. Thoroughly blow out the rotor and stator with dry compressed air from both ends of the machine in order to be effective, the blowing should remove all the dust to the outside of the machine Blow out and clean the filters with a solvent and dry. Wipe all insulators with a dry rag. Brush between the commutator bars with a fibre glass or nylon brush. Check for concentricity of the commutator (or ring) by applying a comparator to the top of a brush. Insulation resistance of windings to be measured four times. When warm, when cold, before and after blowing. Measure with a spring balance the pressure applied by the brush holder pressure fingers on the top of the brushes.
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12. If necessary, measure the wear of the bearings by checking clearances at 90 apart (3 - 6 - 9 and 12 oclock) with a set of appropriate feelers. Measure, if necessary, the length of all brushes on one arm to see if there is abnormal wear Examine the bar chamfers and look for incipient pitting or shading of the bars or burning of the trailing edges and oil leakage. (If the skin appears a little too thick, it is advantageous to pass a flexible abrasive cleaner over the commutator or the rings before putting the machine back into operation). Examine the groove edges of helically grooved rings (a cutting edge on the rim of a helical groove always brings about rapid wear of the brush) and for incipient marks or burns). Carefully check that surface of the commutator or slip-rings is not polluted with oil Note first that there is no copper dust deposited on the brush-holders Check that the contact edges of the brushes are not chipped or burnt and that the surfaces do not have any vibration or burn marks.
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Examine if necessary the interior of the brush boxes for smoothness and cleanliness. Check that the brush flexibles are not oxidised, burnt or frayed. After putting the brushes back into their brush holders verify that they are sliding normally in their boxes, that the pressure fingers are in their correct position at the middle of the top of the brushes, that the flexibles are not pinched by the pressure fingers. Remove all brushes especially if the machine has to spend some time in a humid, salty or chemical atmosphere or put a piece of paper between the brush and the commutator or rings.
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on the front surface indicating the remaining length. Sometimes also the lower edge of the brush marking indicates the wear mark. Usually this wear mark is set 2 3mm below the lowest point of the tamped contacts. Electronic brush wear indicators also may give an alarm, short before the tamped contact touches the collector.
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give rise to major malfunction of the motor. When there has been such intermixing of grades it is often difficult to determine which grade is the correct one; the grade giving the worst performance may well be the one which would behave the best if used alone !
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V
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~
ACcurrent
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wheel must turn in the opposite direction to the rotation of the rotor. For the machining of steel rings coarser stones should be used than for copper or non-ferrous metals. In our experience when machining copper and non-ferrous metal, an SC 80 K4 BA stone is very suitable for the preliminary grinding and an SC 220 K3 BA (DIN 69 100 designation) for finish grinding. If steel rings have to be machined an SC 46 K5 BA stone should be used for preliminary grinding and an SC 80 K4 BA stone for the final machining. When the latter grindstones in each case are correctly applied to the ground surface, they will produce a surface structure with peak-to-valley heights of the order of RZ = 5 8 m (Ra = 0,8 1,2 m) which is favourable for the running-in of carbon brushes
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must be removed. If there is a risk that the insulation bars between the segments are no longer sufficiently undercut after turning or are even flush, they must be re-cut. Both diamond and carbide tipped cutting tools can be used for turning the machines in question when they have undercut segment insulation bars. When the insulation bars are flush only carbide should be used. Diamond is used in metal cutting predominantly to give a super-finish, i.e. it has advantages when surface with minimum peak-tovalley heights have to be produced at high speeds. Since we are not aiming here for any mirror smooth surface finish, carbide may be preferred unless the greater service life of diamond is the decisive factor. Our experience shows that cutting speeds of the order of 160 200 m/min are advisable with carbide tools and 300 350 m/min with diamond tools. The feed should be about 30 m at a cutting depth of 0.05 0.1 mm.
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generally been found that a milled-out depth equal to the width of the insulation is sufficient. It is important to ensure that no mica or insulation residue remains at the edges. The milling out should therefore be wider by about 1/10 mm than the insulation bar which also takes account of possible dividing errors; see the illustration at the left side. The most usual angles for the edge chamfer lie between 60 and 90. Undercutting the segment insulation bars of small machines can be done manually. It is however advisable where a higher quantity of pieces is involved, to use special machines which are offered by the industry for this purpose. If the edges of the segments have to be chamfered, this should be done before the last turning or grinding operation so that any flash which may stand proud can be removed. The grooves must be thoroughly cleaned after machining.
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Thecountermeasures dependontheconcentrationoftheaggressive substance,Incaseofslightcontamination onlyasocalledselfcleaningbrush variantorasandwichbrushdesigncan beused. Itisalsoappropriate insuchcasestousecarbonbrush materialsthatlaydownathickgraphitic patinaasaprotectingfilm.
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top bears on the leading edge area. In this case the reaction moment at the brush becomes very small this is of particular importance when there is variable friction. When the friction force oscillates the reaction moment has the effect of stabilizing the brush and compensates for the friction.
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measurement the value is also not very accurate, but at least reproducable. Temperature test points There are test points for different temperature ranges. These points change colour with temperature They are put onto the collector service and can be checked after some time of running. They give a relatively exact hint of temperature conditions while machine operating.
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5.17. What has to be done if the motor has to be stored for a longer period ?
The following procedures are recommend in case the motor is stored for a longer period in the warehouse : Motors must be stored in a dry, well ventilated area which is free of vibration and dust. Do not remove the rotor shipping brace (if fitted) Open the pressure fingers of the brush holders and take the brushes out of the holder boxes. Remove fitted keys. Protective unit against condensation caused by temperature fluctuations. Protect unit against ingress of aggressive gases such as hydrogen sulfide, chlorine or ammonia. Once a month, remove the rotor shipping brace, turn the rotor by 360 and replace the brace again. Replace the anti-corrosion protection on the shaft extension if necessary.
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to: Before commissioning, remember to: Measure the insulation resistance (see Operating Guide). Check the commutator surface and clean if necessary. Mount the brushes and close the pressure fingers. Lubricate the bearings, clean and grease the bearings if necessary. Insert fitted keys.
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If the surface of the collector is rough, high initial wear may occur. But since the surface is getting smooth quite fast, this problem is only minor. But on a rough surface the graphite of the carbon brush can be deposited much faster. Generally speaking a somewhat rougher surface is considerably less critical for performance than a smooth one. For optimum operation of the brushes, the surface roughness of the collectors must therefore lie within the limits of being not too smooth and not too rough. Trials and experience have shown that a peak-to-valley height RZ of the order of 5 8 m should be aimed at. After machining, the collector surface must not have a very mirror like appearance. Such a surface is a certain sign of too low surface roughness It should rather have a tendency towards a mat finish. If slip rings or commutators are found to be in satisfactory condition before making a replacement and if a good patina has formed on the surface it may be possible to leave them as they are. If, however, they are very smooth and have a mirror finish, it is advisable as already mentioned above to roughen this patina slightly with a grindstone so as to avoid problems in operation
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burning. The brush bounce caused by the larger flat promotes increased sparking and burning and then damage to the brush holders caused by vibration and the trouble is aggravated still further. Flats may be caused by vibration originating from worn bearings, defective gearings or couplings, machine out-of-balance or disturbance fed back from connected plant. Flats may also be caused by the burning which arises from a disturbance of the brush contact by high inter-segment insulation particularly at the edges of segments where the recessing of the insulation has been imperfectly carried out. But more frequently flats are the cumulative result of electrical faults which in the early stages can be recognized by segment burning, by blackening on commutators or by blackened patches on slip rings. Loose or high resistant joints between the armature winding and the commutator cause burning which starts at the segment in advance of the bad joint and then spreads as the burning destroys the contact between commutator and brush. Flats resulting from this cause often have sympathetic flats spread at one pole pitch apart around the commutator and are due to the unbalance in the armature circuit arising from the bad current collection at the original flat. Sometimes bar marking occurs in a regular sequence in which every third, fourth or fifth segment either is burnt or is darker or cleaner than the intervening segments. The segments thus marked occur at slot pitch frequency, according to the number of coils per slot, and this phenomenon is a symptom of unsatisfactory commutation conditions. Slip rings may develop flats from the same mechanical causes as for commutators and an additional electrical reason may be unequal current sharing between brushes. An occasional cause of flatting on slip rings is the tarnishing or rusting of the exposed portion of the rings whilst the machine is hut down, particularly if it is out of service for a considerable time.
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Fluctuationsinthe brushgradeareoftenheldresponsible. Thelistbelowshowssomepossiblecauses: Non-uniformout-of-roundness fromonebrushtracktothenext Non-uniform brush pressure Non-uniform total down-force Non-uniform characteristics of the spring pressure with the brush wear Variable friction in the brush box Differences in temperature Non-uniform current distribution Non-uniform commutation Stability of the brush holders and brush stud assembly Differential polarity Non-uniform brush spacing ( pole pitch) Non-uniform brush orientation Non-uniform brush seating Non-uniform electrical connection
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Indifferent brush bedding Machine Adjustment: Unequal brush spacing around the commutator Incorrect commutation conditions Discoloration of the flexibles in one brush wafer of a twin brush is a typical indication for commutation problems, since the trailing halve of the brush is normally overloaded in case o commutation problems.
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Among the electrical causes the most frequent are: Insufficient brush pressure Current overload due to machine overload, Incorrect current distribution in the brush surface because of commutation conditions, Unequal load distribution between brushes caused by non uniform brush pressure, Unequal circumferential spacing of brushes non uniform air gaps Indiscriminate mixing of brush grades Some brushes sticking in their boxes, giving abnormal heavy wear on individual brushes
Apart from these machine conditions, high brush wear may be caused by the use of an unsuitable brush grade.
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6.8. Why do some commutators show regular light and dark patterns on the segments ?
Sometimes bar marking occurs in a regular sequence in which every third, fourth or fifth segment either is burnt or is darker or cleaner than the intervening segments. The segments thus marked occur at slot pitch frequency, according to the number of coils per slot, and this phenomenon is a symptom of unsatisfactory commutation conditions, i.e. incorrect commutating poles strength or brush position. Because the armature slot is moving with respect to the commutating pole whilst the coils in the slot are passing through their cycle in succession, the commutating field conditions are not necessarily the same for all the coils in the same slot. A small brush shift may assist. When cooling conditions permit, any tendency to produce slot-pitch bar
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marking can be reduced by the use of a brush grade of higher contact drop. Alternatively a brush grade may be used which has a controlled degree of mild abrasive and polishing action. Should either of these methods fail, steps must be taken to widen the interpole flux zone so that a brush position may the be found at which commutation conditions for all the coils in the slot are more nearly alike. This involves changing the commutating pole shoes or commutating pole air gap or both and subsequent re-adjustment of the commutating pole ampere-turns.
SKT / GB4 Page:
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disparity becoming too pronounced it is often advisable to change the polarity of the rings at regular intervals if at all practicable. Where brush current densities and ring cooling conditions permit, brush grades without metal content should be used because ring wear problems are then much less pronounced than with grades of the Metal-graphite class. Brush instability from poor mechanical conditions and insufficient brush pressure can aggravate this ring polarity wear effect.
SKT / GB4 Page:
Schunk Kohlenstofftechnik
Frequently asked questions
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periphery of a commutator.
SKT / GB4 Page:
Schunk Kohlenstofftechnik
Frequently asked questions
Schunk Kohlenstofftechnik
Frequently asked questions
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Schunk Kohlenstofftechnik
Frequently asked questions
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