Reasons for Accelerated Carbon Brush Wear

Motors perform only as well as the carbon brushes that support them, so it is essential that they be properly maintained and replaced when necessary. Sometimes, brushes lose their effectiveness with premature wear. Here are some of the reasons you may find your carbon brushes living shorter lives than expected.

Irregular Spring Pressure

Springs maintain the all-important contact between the commutator and brushes, meaning that unequal spring pressure results in unequal wear. As springs age, so do their ability to keep consistent contact and current distribution. Even brushes mounted in a cartridge with a torsion spring, a mounting designed to maintain proper force between the brush and commutator, can wear out from poor positioning. Checking spring pressure at regular intervals can help prevent uneven wear. 

Download Carbon Brush Troubleshooting Guide

Poor Commutator Conditions

If the commutator itself does not present an even contact surface, that can also lead to accelerated brush wear. Even a slightly out-of-round commutator or ring can cause a domino effect of shortened spring life, inadequate spring pressure, and accelerated brush wear. 

Check Your Commuter Conditions

Contamination
Inconsistent pressure may also result from contaminated components. Excess particulate and carbon dust can prevent proper brush contact with the commutator, which in turn prevents the brush from delivering full current density at the point of contact. Periodically removing build up with compressed air will help keep lingering dust under control and insure more even wear. 

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Environmental Factors

Not only contamination, but temperature, humidity, and frequency of use can lead to accelerated carbon brush wear. Some of these factors can be controlled to a certain extent, others not so easily. Whatever the cause of accelerated brush wear in your particular operating conditions, serious damage may occur if conditions go unchecked.

Regular effective maintenance can increase the lifespan of your carbon brushes, along with a high quality beginning product. Prevent damaged motors and invaluable down time by using our Carbon Brush Troubleshooting Guide. 

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