Beruflich Dokumente
Kultur Dokumente
and Generators
®
have use as contacts and as a base for metal impregnated
Contents grades.
0.40
manufacturing processes and the types of carbons
and other ingredients used. The four main brush 0.30
grade families are:
0.20
Carbon Graphites
0.10
Electrographites
Graphites
Metal Graphites 80 100 120 140 160 180
Brush Temperature - Degrees C
Carbon Graphite Brushes
Figure 1
Carbon graphite brushes made their entrance early in the
brush industry. They are high-strength materials with a
pronounced cleaning action. Carbon graphite brushes are Electrographitic brushes are generally capable of
generally limited to lower current densities 45 amps/in² continuous operation at 80 amps/in² (12.4 amps/cm2) and
(7 amps/cm2) and are used on older, slower speed surface speed of 7000 feet/minute (35.6 m/sec).
machines that reach maximum surface speeds of Intermittent operation at higher values is not uncommon.
approximately 4000 feet/minute (20.3 m/sec). The high They are widely used in the industrial, transportation,
friction generated with this type of material also makes it mining and aerospace industries on both AC and DC
unattractive for present day use on commutators, but does machinery.
1
Grade Characteristic Definitions
Graphite Brushes
The characteristics of the most widely used brush grades
Graphite brushes are composed of natural or artificial are shown in the tables on pages 6 - 10. The following
graphite bonded with resin or pitch to form a layered brush definitions and explanations will help you to interpret these
material. Natural graphite usually contains ash which gives tables.
the brushes an abrasive or cleaning action. Artificial
graphite generally does not contain ash nor does it have the Specific Resistance
flaky structure of natural graphite.
Unless otherwise specified, specific resistance (or
Graphite brushes are characterized by their controlled resistivity) in ohm-inches (micro ohm-meters) is equal to the
filming and excellent riding qualities on both commutators resistance that a specific volume of brush material offers to
and slip rings at brush current densities 45 to 65 amps/in² the passage of current. Specific resistance is measured in
2
(7 to 10 amps/cm ). They are not capable of sustained the length direction of the brush, since resistance in the
operation at higher current densities like electrographitic direction of width or thickness may be considerably
materials; however, higher surface speeds are often different. Specific resistance is calculated from
permitted with some type of graphite materials. measurements on a test sample as follows:
2
3
Contact Drop Maximum Speed
Contact voltage drop for the brushes listed in this brochure The highest peripheral or surface speed in feet per minute
are approximate values only and represent the total voltage (meters per second) recommended for the collector or
drop (positive plus negative) obtained on a copper ring at commutator on which the brush is to ride is referred to as
2 2
50 amps/in (7.75 amps/cm ) while rotating at 2500 f/m the maximum speed. The maximum speed depends not
(12.7 m/sec). only upon the characteristics of the brush material, but also
upon the spring force, current density, type of brush holder,
They are classified as follows: brush angle, condition of the ring or commutator,
atmospheric conditions, etc. Consequently, the maximum
Contact Drop Volts speed, conventionally listed as a brush characteristic, is
Very High 1.7 and above only an approximation.
High 1.2 to 1.7
Medium 0.6 to 1.2 Friction Coefficients
Low Below 0.6
Brush friction is influenced by many variables including
Current Carrying Capacity brush temperature, spring force, current, atmospheric
conditions, mechanical conditions, ring or commutator
The actual current carrying capacity of a brush is widely materials, surface films, speed and other factors. The slip
influenced by operating conditions such as type of ring/commutator surface even under favorable conditions is
ventilation, continuous or intermittent duty, speed and other continually undergoing changes caused by oxidation,
factors. The brush grade current ratings are conservative, abrasion and moisture.
some allowance having been made for overloads. Brushes
have been run at currents considerably above those listed Friction chatter, noise and associated brush wear can be
in the grades table. Metal graphites, for example, have accelerated with certain brush holder configurations. This is
2
been operated at 180 amps/in² (27.9 amps/cm ) on certain especially true under conditions of light loads and lower
high current generators. Electrographitic brushes have brush temperatures when the coefficient of friction is
2
been operated at 100 amps/in² (15.5 amps/cm ) on similar relatively high (refer to Fig. 1). Specific brush grades are
equipment with reasonably good results. used to lessen the severity of friction chatter under these
conditions. Friction between the brush and rotating surface
The current carrying capacity of a brush depends on the can be a major source of heat generation that causes
operating temperature. On well ventilated machines, having serious temperature related problems. Commutators can
small brushes, with large surface area in proportion to their distort, slip rings can move, and brush wear can become
volume, and where brushes cover only a small percentage excessive when the coefficient of friction becomes too high.
of the commutator or ring surface, conventional current
densities can usually be doubled for short periods without The brushes are classified as follows:
seriously jeopardizing the performance. However,
increasing current density without making provisions for Friction Friction
maintaining a low brush temperature may severely reduce Classification Coefficient
brush life. The brush current density of a given machine can High 0.40 and above
be calculated as follows: Medium 0.22 to 0.40
Low Below 0.22
3
4
St = 3 x P x L / ( 2 x W x T²) Brush Description and Application
St = transverse strength in PSI (Kgf/cm2) Grade Recommended for:
P = the total force in pounds (Kgf) applied at the A good commutating grade with slight polishing
upper knife edge L932 action operational range is 50 to 75 APSI (7.75
APSC to 11.6 APSC).
L = distance between supports in inches (cm) L944 Treated grade fir improved life.
W = width of sample in inches (cm) A good commutating grade with slight polishing
L963
action, also treated for low humidity protection.
T = thickness of sample in inches (cm) L964 Stronger base material for improved life.
Similar to L932, provides improved filming vs.
L966
L932.
Low friction base material, with slight polishing
L983 action used in stubbing/leading (brush holder)
configurations.
Table I
4
5
generator and smooths the commutator and/or collector
Morgan AM&T manufactures a full line of rubber hardtop ring to a specific roundness as the machine operates. The
brushes, also known as pads, designed to soften the impact SRB does not limit the apparatus output since it is made of
from a rough commutator, giving longer brush life and the material compatible with the other brushes. SRB’s will
reducing brush breakage. However, rubber hard top remove metal as they slowly grind off the high areas. For
brushes are not a “cure-all” solution. For more information more information on SRB’s, refer to the technical data sheet
on rubber hard top brushes, refer to the technical data on Surface Rounding Brushes.
sheet on Rubber Hardtop Brush Applications.
5
Engineered Brush Grades
Electrographitic
Spec. Trans. Surface Normal
Res. Strength Con- Speed Current Description and Application
Brush Ω-in. Dens. lbf/in² tact Fric- ft/min Density
Grade (µΩ-m) g/cm³ (kgf/cm²) Drop tion (m/sec) A/in²
(A/cm²) Recommended for:
0.0020 3700 6000 80 A variety of industrial and FHP machines.
234 1.48 VH L
(51) (260) (30) (12.5) Good general purpose grade.
Copper alloy slip rings with current density
0.00075 2700 6000 80 up to 75 APSI and speeds up to 6000
258 1.60 H L
(19) (191) (30) (12.5) ft/min. Also used on lightly loaded
machines.
0.0030 1700 8000 80 Where excellent commutating ability is of
561 1.54 VH M
(76) (120) (41) (12.5) primary importance.
0.0029 Contaminated atmospheres where slight
1600 8000 80
569 (74) 1.53 VH M polishing action is necessary.
(113) (41) (12.5)
0.0027 2400 7000 80 Industrial and transit applications.
571 1.57 VH M
(66) (169) (36) (12.5)
0.0022 3200 6000 80 Mill-type motors and generators where
581 1.61 VH M
(56) (225) (30) (12.5) normal commutation is needed.
0.0024 3700 6000 80 Where high strength and superior
590 1.62 VH M
(61) (260) (30) (12.5) commutating ability is needed.
0.0020 4000 6000 80 Where severe mechanical conditions
591 1.66 VH M
(51) (282) (30) (12.5) require a high strength grade..
0.0026 1400 8000 80 Where humidity is low or where filming
A451 1.50 VH L
(66) (99) (41) (12.5) conditions are difficult.
5
6
Electrographitic (continued)
7
8
Electrographitic (continued)
Graphite
8
9
Metal Graphite
Spec. Trans. Surface Normal
Res. Strength Con- Speed Current Abra % Description and Application
Brush Ω-in. Dens. lbf/in² tact Fric- ft/min Density siven Met
Grade (µΩ-m) g/cm³ (kgf/cm² Drop tion (m/sec) A/in² ess al
(A/cm²) Recommended for:
24 – 50 volt DC motors and AC
0.0003 3200 6000 100
537 2.77 VH M L 48 motor collector rings where low
(8) (225) (30) (15.5)
humidity protection is required.
High current/low voltage
0.00016 4700 6000 100 40
AJT 3.00 L L L motors exposed to high
(4) (331) (30) (15.5)
altitudes.
Where high copper content
0.000006 3500 6000 150
ANK 4.95 L L M 75 and low humidity protection is
(0.2) (246) (30) (23.3)
needed.
0.000044 5000 4000 100 Applications of wound rotor
AYK 2.64 M M L 40
(1.1) (352) (20) (15.5) motor rings up to 100 APSI.
Appliance motors and other
0.0450 2300 4000 40
F83 2.02 VH L L 25 FHP applications and suitable
(1143) (162) (20) (6.2)
for low current densities.
Low-voltage motors,
particularly switch and signal
0.000014 3100 5000 125 equipment. Also used on
L4 4.57 L H M 75
(0.38) (218) (25) (19.4) plating generators up to 15 volt
and on brass slip rings of
induction motors.
0.000125 3500 7000 100 Slip rings and low voltage
M2650 2.80 L L L 50
(2.79) (246) (36) (15.5) motors (24 – 72 volts).
0.000025 3800 6000 110 Slip rings and low voltage
M2665 3.50 L VL L 65
(0.76) (268) (30) (17) motors (6 – 24 volts).
Slip rings and low voltage
motors (6 – 24 volts). Also can
0.000008 3200 6000 125
M2675 4.25 L L M 75 be used on slip ring
(0.23) (225) (30) (19.4)
applications when higher
current density is needed.
0.000015 8000 6000 150 Plating generators up to 15
M2688 5.40 L L M 88
(0.38) (563) (30) (23.3) volts and conductor rolls.
Where very low contact drop,
0.000008 2400 4500 150 and low friction are required.
M407 5.10 L M L 75
(0.2) (169) (23) (23.3) Also used on controllers and
control equipment.
0.000015 8300 5000 140 Low-voltage machines and
M540 5.40 L H M 85
(0.38) (584) (25) (21.7) grounding brushes.
Low voltage, high current
0.000012 6000 4000 150 applications where long brush
M5N 5.91 L M M 96
(0.3) (422) (20) (23.3) life and minimum collector
wear is desired.
Low-voltage DC motors and
0.00027 3000 6000 100 generators in the 24 to 72 volt
M785 3.20 L H L 50
(7) (211) (30) (15.5) range and on brass slip rings
of induction motors.
The information contained in this tabulation of material properties is based on experimental and / or historical trends and indicates guidelines
for typical lots of materials. Choosing the correct grade for a particular application should not be based solely on physical properties. No
guarantee of these properties is given or implied.
9
10
Brush Request Form
Six Steps to Identify a Carbon Brush
Manufacturer _____________________
Application General Industrial Steel Mill Tamed Rivet Insulated Measuring Length
Papermill Elevator
5
Mining Power Gen
Other ___________ Describe The Brush Top
Describe ___________________________________
Solid
Plytek
Triply
Quick Disconnect EZ Terminal
Advanced Materials & Technology Fill out the form and fax to 205.252.3600. Then call a
www.morganamt.com Customer Service Representative at 800.858.3366.
11
Electrographite Grades
SA4542
SA4548
DE7000
DE9000
N6000
SA35
SA45
SA50
DE25
N964
Applications
T508
L932
L944
L966
T300
T416
T500
DE8
N19
N39
N44
N48
N66
234
AY
D
light load
moderate load
Paper Mills
heavy loads
contamination
auxilary motors
collector rolls
dc cranes
generators
Steel Mills
looper motors
low voltage generators
rolling mill motors
contamination
excavator generators
Mining
excavator motors
generators
Elevators
hoist motors
exciter generators
Power hydroelectric
Generation steam turbine slip rings
wind generators
light loads
moderate load
Industrial
heavy loads
contamination
alternator
grid blower motor
Railroad
light rail
traction motor
alternators
Off Highway grid blowers
wheelmotors
annealers
container cranes
electric vehicle pump
electric vehicle traction
grounding
plastics
Misc
rotary conversion
shears (hi inrush)
ski lifts
slip rings - bronze
slip rings - steel
wound rotor motors
The applications of brushes to all types of electrical machines is numerous and varied. This grade
/ application matrix is intended to give general recommendation guidelines for many of those
applications. These recommendations are the product of intensive research, development, and
experience of our Application Engineers in both the laboratory and in the field and cover a wide range
of service conditions. This process is a continuous development program and we are always striving to
recommend the best grade for each application.
12
Graphite Grades Metal Graphite Grades
M2650
M2665
M2675
M2688
M407
R310
R312
R318
R320
Applications
T508
T550
T563
T566
T573
T583
T606
T652
T758
T825
T869
T900
T959
T341
T990
T500
M5N
634
537
L4
light load
moderate load
Paper Mills
heavy loads
contamination
auxilary motors
collector rolls
dc cranes
generators
Steel Mills
looper motors
low voltage generators
rolling mill motors
contamination
excavator generators
Mining
excavator motors
generators
Elevators
hoist motors
exciter generators
hydroelectric Power
steam turbine slip rings Generation
wind generators
light loads
moderate load
Industrial
heavy loads
contamination
alternator
grid blower motor
Railroad
light rail
traction motor
alternators
grid blowers Off Highway
wheelmotors
annealers
container cranes
electric vehicle pump
electric vehicle traction
grounding
plastics
Misc
rotary conversion
shears (hi inrush)
ski lifts
slip rings - bronze
slip rings - steel
wound rotor motors
There is a total cost consideration of commutators / slip rings and brushes when making decisions to
apply a brush material. A balance between good brush life versus commutator or slip ring wear that
must be calculated and should be the final basis for grade selection.
e
to There is no guarantee given or implied in these recommendations.
13
14
COMMUTATOR
COMMUTATOR SURFACE
SURFACE CONDITIONS
CONDITIONS
Satisfactory Conditions
Satisfactory Conditions
Light Film - over the entire commutator Dark Film - if uniform over the entire Blotchy Film - this nonuniform filming Slot Bar Filming - repeating light and
Light
surfaceFilm
is one- ofover the entire
the many normalcommutator
conditions Dark
commutator - if uniform
Film surface over the entire
is acceptable. This Blotchy
condition isFilm
the most nonuniform
- thiscommon filming
appearance. Slot
dark fiBar
lmingFilming repeating
patterns -related to thelight and
number
surface is one of the many normal
often seen on a well functioningconditions
machine. commutator surface is acceptable.
condition can be the result of a high This condition is the most common appearance.
The accumulated tolerances in the machine dark fi lming patterns related to the number
of armature coils per slot. This pattern is
often
Film tone
seenison a well functioning
dependent machine.
on the brush grade condition can be the result
filming brush grade, higher currentof a high The
suchaccumulated
as commutatortolerances
roundness, the machine
in brush contact of
dependent
armature on coils
theper slot. This
machine pattern
design is
and
Film
and current dependent on the brush grade
tone is density. filming brush
densities or the presence
grade, ofhigher current
chemical vapor such as commutator
pressure, unequalroundness,
magneticbrush
fieldscontact
and dependent
usually not aon the machine
function design
of the brush and
grade.
and current density. densities or the presence of chemical vapor
contamination. pressure, unequal
chemical vapors all contribute
magneticto fields
this typeand
of usually not a function of the brush grade.
contamination. chemical vapors
film development. all contribute to this type of
film development.
Concerned Conditions Unsatisfactory Conditions
Concerned Conditions Unsatisfactory Conditions
Streaking - of only the film is not detrimental Bright Spots - a freckled appearance of Bar Burning - is the erosion of the trailing Slot Bar Burning - results in commutator
Streaking - of only the
to the commutator. Brush
film and detrimental
is notcommutator Bright
the film usually - a freckled
Spots caused appearance
by machines that areof Bar
edgeBurning - is the erosion
of the commutator bar. Failed trailing
of themachine Slot
erosion
BarofBurning
every second, in commutator
- resultsthird, or fourth
to
lifethe
arecommutator.
not at risk in Brush and commutator
this condition. If metal the film usually
subjected to frequent by machines
causedoverload cycles.
thatIf are
the edge of the commutator
components, maladjusted bar.
electrical machine
Failedsymmetry erosion
bar depending
of everyonsecond,
the winding or fourth
third, design of
life are not
transfer develops, in this
at risk this condition.
condition If metal
will progress subjected
bright spots frequent
to disturb overload
only the film, cycles. If the
a machine components,
of the machine maladjusted electrical symmetry
or a poor commutating brush bar depending on
the armature. the winding
Improper brush design of
material,
transfer develops, this condition will
into threading. This type of filming can progress bright spots disturb only the film, a machine
can operate for long periods of time with this of the machine or a poor commutating
can result in bar burning. If not corrected, brush the armature. Improper brush material,
brush design or electrical adjustment of
into
be dependent
threading.on Thiscurrent of filming
typedensity can
or brush can operate
condition. If severe periods
for longmetal of time
transfer with this
begins, the can result in bar burning. If not
this condition can cause severe commutatorcorrected, brush
the machine
designcan electrical
or cause this condition. of
adjustmentThis
be dependent on current density or brush
grade. condition.
bright spotsIf could metal transfer
severeprogress to dangerous
begins,bar the this condition
damage or a can cause severe commutator
flashover. the machine
condition can cause
severely damages this condition. This
the commutator
grade. bright
burning spots
or ficould progress to dangerous bar
lm stripping. damage or a flashover. condition severely
and reduces brushdamages
life. the commutator
burning or film stripping. and reduces brush life.
Unsatisfactory Conditions
Unsatisfactory Conditions
life are not at risk in this condition. If metal subjected to frequent overload cycles. If the components, maladjusted electrical symmetry bar depending on the winding design of
transfer develops, this condition will progress bright spots disturb only the film, a machine of the machine or a poor commutating brush the armature. Improper brush material,
into threading. This type of filming can can operate for long periods of time with this can result in bar burning. If not corrected, brush design or electrical adjustment of
be dependent on current density or brush condition. If severe metal transfer begins, the this condition can cause severe commutator the machine can cause this condition. This
grade. bright spots could progress to dangerous bar damage or a flashover. condition severely damages the commutator
burning or film stripping. and reduces brush life.
Unsatisfactory Conditions
Threading - is machining of the commutator Pitch Bar Burning - results in commutator Grooving - is the uniform circumferential Copper Drag - occurs when high energy
by copper particles in the brush face. The bars being eroded in a pattern related to wear, the width of the brush, that is exhibited transfers copper in a molten state. These
excessive copper transfer occurrs due 1/2 the number of brush arms, progressing on the commutator. Excessive abrasive dust particles become coated by contaminants
to low spring pressure, light loading or into a pattern equal to the number of brush in the atmosphere or an abrasive brush can from the surrounding environment or the
contamination. These particles are trapped arms. This condition is caused by a cyclic cause this condition. Extreme light spring brush treatment and do not oxidize properly
in the porous carbon brush and work mechanical or electrical disturbance such as pressure (below 1.5 psi) can also cause this to form the film on the commutator surface.
harden, creating a tool that machines or an unbalanced armature, misaligned shafts, condition. Proper brush applications and These particles accumulate at the edge of the
gauls the commutator surface. The machine bent shaft, bad bearings, weak foundation, filtering the air on force ventilated motors can bar, eventually shorting across the insulating
can operate for long periods of time with failed equalizers or a poor riser connection. reduce the commutator wear. Some people mica. This condition needs to be addressed
this condition, but reduced commutator and If not corrected this condition will result in a call this “Ridging” because of the resulting immediately when discovered or serious
brush life will be experienced. flashover. ridges on each side of the groove. damage may occur. Chamfering the
commutator bar edges is necessary to stop
Call our Application Engineering Dept. the progression of this condition.
if you would like help improving your
Commutator Condition or Brush Performance.
864-458-7777 or 1-800-543-6322 NAT SCP 4/08 INDEXX
251 Forrester Drive
Greenville, SC 29607-5328 USA
1.800.543.6322
1.864.458.7777
®
www.morganamt.com
NAT CPO1 9/09 500
64011023