Components of Brush DC Motor
There are several elements of a brush DC motor. Among these are the stator, commutator, axle, magnets, armature, and brushes. A stator, or armature, surrounds the rotor. A stator generates a magnetic field using either permanent magnets or an electromagnetic winding. The axis of the rotor has a copper sleeve, called the commutator. The commutator handles the windings’ mechanical commutation.
Carbon brushes are one of the many different components found in DC motors. They are an integral part of the operation of the motor, so it is imperative that to maintain them using a regular inspection schedule. Repairs are necessary from time to time, and brush replacement is common.
Reducing wear on the commutator is the primary job of a DC brush. Brushes also transfer electricity to the center of the motor. The main component of a brush is carbon because it is self-lubricating. Because of this feature, they are less likely to experience wear and tear in comparison to other types of brushes. Other brush options include steel and copper.
These brushes are also considered as the motor’s most vulnerable parts prone to wear because of motor overuse. Possible overuse leading to excessive brush wear is one limitation of a brush DC motor. Brushes are easy to replace. Used and maintained under normal circumstances, carbon brushes last longer.
Functions of a DC Motor
There are several types of industry that rely on a brush DC motor because of its functionality and performance. For instance, it is common in the automotive industry since the motor is cheap. The DC motor has simple and straightforward features. These features make them useful in making power seats and windows, to name a few.
There are different speed and torque specifications in a brush DC motor. Plus there are various sizes of the motor available, depending on your needs. For any motion control applications, brush DC motors are excellent options because of its high torque and speed.
Problems with Brushes
Premature wear of the carbon brushes leads to problems within the motor. Brushes fail for many different reasons, including:
- Voltage surges
- Winding faults
- Incorrect installation
- Electrical overload
- Excessive sparking from worn brushes
The soft metal design creates more malleable brush contact on the commutator. Sparking on the commutator occurs before carbon brushes experience excessive wear. When worn down, expect problems with motor performance. Over time, the motor becomes damaged and fail.
With proper maintenance, it is possible to extend the life of carbon brushes within DC motors. Regular brush testing, as part of a preventative maintenance program, goes a long way in solving this problem. Conduct regular visual inspections. Be aware of potential problems that signify carbon brush wear. These excessive wear issues include a reduction in power, excessive sparking, and motor failure.
Conclusion
To ensure the lifespan and performance of a brush DC motor, keep all brush components in good condition. Maintain the DC brushes and replaced them when necessary. Healthy brushes impact the longevity of the motor.
With proper care and maintenance, the brush DC motor lasts for up to 2,000 or even 5,000 hours of use. These estimates, of course, depends on the design, voltage, speed, and operating current of the motor.
For brush surveys and all other DC motor needs, contact L&S Electric. We perform routine testing and repairs, according to your needs.
