Failure of Small Generators To Produce Electricity Due To Carbon Brush Wear

I. Function and Structure of Carbon Brushes

- Carbon brushes conduct current, enabling the rotor to function as an electromagnet.

- The brush contact points are made of graphite, which provides self-lubrication.

II. Analysis of Carbon Brush Wear Causes

1. Usage-Related Causes

  - Dust in the operating environment accumulates on the copper slip rings.

2. Production Process Issues

  - Small contact area between the carbon brush and the copper slip ring leads to overheating.

  - Incorrect installation angle exacerbates wear and can cause brush arm breakage.

  - Manufacturing standards vary between factories; for example, insufficient smoothness or burrs on the copper slip ring will accelerate carbon brush wear.

III. Solutions

- When using a generator in a dusty environment, the wear condition of the carbon brushes must be checked regularly.

- Select products and suppliers with better quality control and assembly standards to prevent premature carbon brush wear.