Is it possible to learn more about the process of making carbon brushes?
When it comes to making carbon brushes, we’ll take a look at some of the key processes.
What are Carbon Brushes?
It is possible to wear carbon brushes, which act as a conductor of electric current between rotating and stationary parts of a generator or motor.
As a conductor of electricity, carbon is ideal, but it’s also soft enough to maintain a steady contact point.
As a result, you’ll need to replace them when they’ve reached their limit of usefulness.
Please visit this page to find out more about carbon brushes.
How Carbon Brushes are Made
1. Creating the Carbon Block – The Right Material is Key
To begin, a block of carbon must be made from which the brushes for this batch will be carved out by hand.
Materials are combined in a certain way to match the voltage and wattage of the power tool they’ll be utilised with.
There are a number of different materials that may be used to make power tool brushes, including carbon-graphite, copper graphite, and silver graphite.
2. Design the Carbon Brush & Cut it to Size
As a result, you need to ensure that the carbon brush’s dimensions match those of the carbon brush holder it will be inserted into.
Making the designs and reducing them down to size is a necessary step in this process.
3. Grind the Carbon Brush Body Smooth
It is critical to maintain a constant contact point, thus the brush must be grinded until the edges are smooth.
4. Check Measurements of the Brush Body Against Specs
This is a precautionary measure to check that the brush still fulfils the specifications. Negative tolerances of -0.1mm to 0mm are permitted..
5. Create a Hole and Embed Wire
A conductive wire must be inserted into the carbon brush to link the tool to the static component, so we drill a hole in the brush and insert the wire.
6. Weld the Wire to the Terminal
The termination must be welded to the wire’s other end before it can be used with the power tool system.
To guarantee the carbon brush has the correct pressure on the Commutator, certain brushes feature a spring design that has to have the correct tension, length, diameter, and thickness. The carbon brush’s spring design must also be taken into account when the final product is being made.
Don’t Use Carbon from Old Batteries
Carbon brushes can reportedly be made using the carbon in old batteries, according to internet rumours and instructions.
Because the carbon utilised is so hard, this is quite risky and can cause serious damage to your tool.
Instead of throwing away your old brushes, you’d be better off investing in some new ones..
What does a poorly made carbon brush look like?
When it comes to carbon brushes, bad craftsmanship is evident in the following ways:
- Inconsistent edging.
- When heated, it softens and degrades.
- Is responsible for the darkness in the carbon brush holder.
- Rubber-burning stench.
You can contact TDO Carbon to buy new carbon brushes online today.