Split brushes consist of a several sections or wafers and provide a better dynamic response (i.e., the sections provide a larger number of contacts points and can conform more quickly to the commutator, especially in reversing conditions). Multi-section split brushes have greater resistance because of the internal resistance generated between individual segments. Different brush materials can be used in different sections to provide hybrid characteristics. Multi-section brushes are usually padded to evenly distribute the applied load across the sections while improving damping.
Sandwich brushes are a special type of split brush in which the wafers or segments are bonded together and do not move independently. The bonding material can be an insulator, which can also polish the commutator surface.
Paired brushes consist of two separate brush blocks, usually connected together by a shunt. A tandem brush is a specialized type of paired-brush set in which the two brush pairs are contained within separate compartments of the same brush holder.
The brush is provided in the form of an assembly of a button that is attached to a cup which holds the brush. The cap can be attached to a threaded stud or spring, which is then connected to the power terminal.
The contact or brush assembly consists of a leaf-spring type of integral spring which maintains sufficient contact-force to assure low-contact resistance. The leaf can be attached to a threaded stud or spring, which is then connected to the power terminal.
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Brushes are provided in the form of a spring-and-cap assembly. The tamped brush has a shunt which passes through a spring and is connected to the cap. The electrical connection is provided through the cap. Cap-and-spring brushes are used typically in fractional horsepower motors and other lower power applications.
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Carbon graphite provides a cleaning action at low speeds. Carbon graphite was one of the first brush material grades developed and is found in many older motors and generators. It has an amorphous structure.
Graphite brush-material grades are used in applications that require low friction. They are used at very-low current densities and very-high peripheral speeds. Graphite, flake graphite, and graphitic carbon have a hexagonal, crystalline structure that cleave or shears easily, making graphite a soft material and effective lubricant. A form of carbon, graphite has an anisotropic hexagonal crystal structure.
Graphite is the most commonly used EDM electrode material because of its good machinability, wear resistance, and low cost. Like carbon, graphite is a non-metallic substance with an extremely-high sublimation temperature which provides resistance to high-temperature arcs. Fine, grain-sized graphite tends to have better erosion and wear performance, but costs more.
Electrographite brush-materials are processed with a special high-temperature method that stabilizes the graphite. Electrographites are the most common graphite grades used in newer motors, generators, and electrical equipment. Electrographites provide good performance at higher levels of voltage, current density and speed.
Metal graphite is a composite mixture of graphite and a metal, usually copper, which provides higher conductivity than pure graphite and lower friction or sticking than pure metal in sliding contact applications. Typically, the metal addition bonds the graphite together, forming continuous high-conductivity paths and a lower voltage drop. These characteristics enable metal graphite brushes to perform well under high current-density and low voltage conditions.
Copper graphite is a composite mixture of graphite and copper metal (~15 to 95%), resulting in a material with higher conductivity than pure graphite and lower friction or sticking than pure copper in sliding contact applications. Typically, the copper bonds the graphite together to form continuous, high-conductivity paths and a lower voltage drop. These characteristics allow copper graphite brushes to perform well under high current density and low voltage conditions.
Copper graphite is more expensive than other materials, but provides better conductivity and flexural strength than pure graphite. Copper's higher strength is useful for fabricating thin section EDM electrodes.
Contact materials consist of graphite particles dispersed in a matrix of silver. Graphite has a high melting point (high refractoriness) and is insoluble in silver, resulting in superior anti-welding characteristics in high power and cycle applications such as circuit breakers. The graphite burns ups in the arcing or switching process and maintains a clean, low-resistivity contact surface. The silver typically bonds the graphite together, forming continuous high-conductivity paths and a lower voltage drop. These characteristics allow silver graphite brushes to perform well under high current density and low voltage conditions. Silver is more oxidation-resistant than copper, which can maintain cleaner contact surface during down times.
Silver has the highest conductivity of all metals. The high conductivity, softness or low hardness and high resistance to oxidation make silver an excellent choice for contact materials. Silver is strengthened with additions copper, but at the sacrifice of conductivity. Fine silver is silver with very high purity (99.99% Ag). Pure or fine silver is too soft for most commercial applications, but the material is used as a starting component to form other silver based alloys.
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The thickness is typically the smallest dimension of a pad, block, strip, sheet, or plate material. According to ISO, EN or DIN brush standards, thickness is defined as the dimension tangential, or in the same rotation direction as the commutator or slip ring.
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This is the outer diameter (OD) or width of a component or stock-form material such as a pad, block, strip, bar, plate, or tube. This measurement may also represent the outer diameter or width of fabricated components such as electrodes or contact tips. According to ISO, EN or DIN brush standards, the brush width is the axial dimension, parallel to the motor or generator shaft.
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This is the length of a component or stock form material such as a pad, block, strip, bar, rod, plate, or tube. Typically, length is the largest dimension of the component. According to ISO, EN or DIN brush standards, the brush length is the radial dimension, or the dimension perpendicular to the commutator or slip ring.
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The rated current is the maximum recommended current load that the material is capable of handling. For static contacts or connectors, rated current is the current that a device can carry continuously without overheating. For opening and closing contacts in devices such as circuit breakers, contactors or switches, rated current is the current a device can carry while switching.
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Electrical brushes or sliding contacts are designed for bearing protection applications. Specialized brush assemblies can be used to provide a grounding action, which protects the bearing components against electrical arcing and pitting damage from electrical paths conducted through the bearings.
Electrodes, brushes or contacts are designed for sliding contact applications in which the contacting members that provide the electrical path slide against each other (e.g., a brush sliding against commutators or slip rings in generators).
Electrical brushes, sliding contacts, or electrodes are designed or suitable for mobile electrification applications such as festoon or conductor rail systems. Mobile electrification systems provide power to moving vehicles and equipment such as automatic guided vehicles (AGV), mobile hoists and cranes in automated factory, material handling and other specialized applications.
Brushes designed for sliding contact applications where the contacting members providing the electrical connection or path for transmission of power or signals across a rotary interface in motors, generators or other specialized rotary electrical application.
Electrical brushes, contacts or electrode components are designed or suitable for original equipment manufacturer (OEM) or new equipment applications. The components are often adjusted for the specific product or new equipment under development by the OEM.
Electrodes, brushes or contacts are designed for sliding contact applications in which the contacting members that provide the electrical path slide against each other (e.g., a brush slides against a conductor rail in rail, transit or mobile electrification applications).
Electrodes, contacts, contact assemblies or brush assemblies are designed for repair or replacement in various breakers, motors, or other electrical equipment while maintaining or improving performance characteristics.
Electrodes, brushes or contacts are designed for transmission or pick-up of electrical signals in testing, probing or instrumentation applications. Contacts for these applications require very low contact resistance and high reliability, such as transmission of strain gage, thermocouple and tachometer signals. The contacts must maintain a low contact resistance even under low power conditions to avoid the introduction of noise into the signal.
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Brushes, contacts or electrodes are designed or suitable for use in Baldor Electric motors, generators, gear motors, grinders, or other power equipment.
Brushes, contacts or electrodes are designed or suitable for use in other unlisted OEM motors, generators or power equipment.
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The bottom face of the brush has a concave or inward-radiused surface that conforms to the convex or round mating surface of a commutator of slip ring.
Silver graphite brush contacts are lubricated with molybdenum disulphide or another internal lubricant to reduce friction and improve lubrication characteristics.
The brush or brush assembly has a hard rubber, fiber or plastic pad adhesively bonded to the top of the brush. The pad evenly distributes the applied load across the top of the brush and improves damping ability. Typically, multi-section brushes use padding to improve load distribution across the individual sections.
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