Carbon Brush
A carbon brush is a special electrical conductor designed to make contact with stationary and rotating components of electrical systems. They are designed to make sliding contact between two electrical parts.
It implies that as your brushes slide on the stationary components, they facilitate the flow of electrical current.
Angle Grinder Compatible Carbon Brush
High-quality Motor Carbon Brush
Generator Carbon Low-fuel Consuming Brush
Essential Round Carbon Brush
Power Tool Carbon Brush for Electric Pick
High Precision Machine Carbon Brush
Carbon Brush for Black & Decker
Universal Carbon Brush Accessories
Why Use Motor Brushes
Firstly, a carbon brush is a conductor that makes contact between stationary and rotating parts of electrical systems such as motors, or generators. By doing so, it ensures electrical components function optimally. At the same time, it minimizes possible wear and tear on the main electrical components.
Secondly, they help produce the right torque for your machines to function. In most cases, rotating power tools require a specific torque to cut or drill a work-piece.
Carbon Brush Uses
Electrical Motors
Electrical motor brushes are the main link between stationary wires, rotors, and armature coils.
Alternators or Generators
They help to conduct electricity through the alternator or generator.
Power Tools
Power tools such as drills, and grinders depend on carbon-brush for their operations. Ideally, any electrical component using motors for its operations will most likely have these carbon brushes.
Classification Carbon Brushes
Depending on your electrical equipment that requires brushes, you can consider any of these options:
| Classification | Features and Recommended Uses |
| Pure carbon brush | · Known for high strength and suitable for electric motors
· Recommended for low current density |
| Electro-graphitic carbon brushes | · Superior commutating capability
· Best for both low-temperature and high-temperature conditions · Known for high-strength · Work well in most contaminated environments |
| Metal graphite carbon brushes | · May contain copper, lead, silver, or tin depending on performance requirements
· Known for low resistivity · Best for high brush current densities and low voltage |
| Graphite carbon brushes | · Characterized by low commutator threading |
In addition to these, East Carbon offers special designs for unique applications:
- One-piece brushes – It is also called solid carbon brush. They are the simplest designs that fit any electrical system.
- Split carbon brushes – They have two or more sectors within a single unit, which produces more electrical contact points.
- Spring-loaded carbon rushes – These brushes have springs that help during installation and normal operation.
Whether you are looking for a generator or motor brushes, they determine the performance of the electrical system. Therefore, you must choose brushes with superior features and design to achieve the performance characteristics you desire.
Excellent Lubrication
Carbon or graphite has a low friction coefficient. This is attributed to the layered crystal structure.
As a result, carbon brushes are self-lubricating electrical parts. Therefore, you will not experience any friction or abrasion. At the same time, the possibility of sparking is virtually minimal.
Better Conductivity
These brushes should make sliding electrical contact between stationary and rotary parts. Therefore, it must have superior electrical conductivity.
Highly Durable
On average, carbon graphite brushes can serve your electrical component for 2 to 10 years.
Still, factors such as low coefficient of thermal expansion, and resistance to melt-down or softening make these electrical motor brushes more durable.
Making carbon brushes is a sequential process involving many stages:
1. Choosing Material for the Brushes
Although carbon forms the primary material in brushes, you may add other elements depending on the application requirements. For example, to achieve high conductivity, you will add copper.
At East Carbon, we offer many material options including copper graphite, silver graphite, natural graphite, or bonded carbon as motor brush material. For better performance, you may add phenol alongside other resins.
2. Mixing and Compacting the Mixture
You will mix all materials in the right proportion. Then use the die and punch tooling system to compact the material. The material will take the shape of the tooling system.
3. Sintering the Carbon Brushes
Next, you will “bake” the carbon brushes at a temperature of about 1200 °C. This fuses all materials to form a solid material. After sintering, subject the brush to a special heat treatment called graphitization.
4. Post Sintering Operations
At this stage, you already have the carbon brushes. However, to improve performance, you can grind or impregnate the brushes with special additives such as oil or resin to improve performance.
Before replacement, East Carbon recommends you let an expert assess your electrical equipment. Although these are some indications that your carbon graphite brushes may be faulty, they require confirmation.
- When there is visible wear and tear (about ¼ of an inch)
- Visible crumbling, or burning
- Poor performance of electrical equipment
- There is a “strange noise” as the machine/equipment rotates especially around the brush area
- Constant sparking around the brushes
