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  Defects in Brushes and Brush Gear

The usual Defects in Brushes and Brush Gear Areas are as follows:

(1) Not correct grade of brush and improper brush tension

(2)  Not proper bedding of brushes.

(3) Carbon brush chattering because of:

(a)   Excessive clearance among the carbon brush and its holder.

Fit up accurate size brush. It has to be good slide fit in its holder. Clearance should not be more than 2 mils.

(b)   Excessive overhang of brush

Generally, the clearance among the bottom edge of brush holder and the commutator have to be only be 1.5mm (1/16 In.) or less. The brush holders should be correctly reset and secured in position that is why the clearance is correct.

(4)  Carbon brush too tight in holder

This is usually because of accumulation of carbon dust. All carbon brushes should be eliminated completely out of the holders one time a month at least. Accumulated carbon dust should be blown off through compressed air and both the brush and the holder cleaned carefully along with dry cloth. Carbon brushes must slide freely in the holder.

(5) Brush tail connections

They have to be secured correctly. If the tail connection  not properly secured strands are damaged, new brushes should be fitted.

(6) Excessive wear of brush

Generally, carbon brushes should last for various months. Excessive wear is exact sign of poor commutation, it needs detailed investigation. If the worn-out brush is not replaced fast, the metallic pig tail connection imbedded in the carbon brush might damage the commutator badly.

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