Brush Test Considerations

How Should a Brush Test be Performed ?
Running a meaningful brush grade test requires gathering and recording data accurately. It
also requires knowing the same life and performance data on the previous brush grade so a
meaningful comparison can be made.
In this day and age, digital pictures of the commutator surface should be taken to clearly
document the film formation of the previous grade and comm. condition. A 2 or 3 mega-pixel
resolution is good enough and keeps the .jpg file size reasonable. One should double check
any pictures taken to make sure they are in-focus before you leave the mine-site, since
accurate comparisons of film formation, copper drag or grooving can not be made without
good photos. When taking pictures closer than 18 inches, remember to use the camera’s
close-up function. Pictures also work much better than relying on one’s memory to make
these comparisons when the test is completed. Including a light blue 3 x 5 index card in the
picture with at least grade, part # and date marked on it with a sharpie marker, will help avoid
mix-ups when comparing photos. The existing commutator film should be removed with a
rubber stone or seater stone to prevent possible cumulative or conflicting filming. The new
brush grade should be allowed to develop its own film on a fresh copper surface.
The film that each brush grade develops is unique, and influences the contact voltage drop
and friction between the brush and commutator. This contact voltage drop directly correlates
to the amount of current each brush will conduct. It is for this reason that brush grades
cannot be mixed within the same motor or generator under test. You would not get
meaningful life data if one grade conducts more current ( does more work ) than the other
brushes within the same machine. Many large generators have 48 brushes, which basically
means the current is trying to divide equally into 24 parallel paths. The current will never be
identical in every brush but mixing brush grades or brush spring forces only invites
selectivity or non-uniform current distribution which will not give meaningful test data.
Selecting a motor or generator with a reasonably smooth commutator surface is also

important. Testing brushes on a degraded comm. surface will not give reasonable
comparative data. If the motor is sparking due to a rough commutator with the original grade
then the new grade will probably spark too. The main purpose of the brush is to conduct
current from it to a rotating commutator or slip ring. It also needs to conduct current to each
and every comm. segment. If the brush does not have intimate contact with each comm.
segment, it still tries to do the job but the current is being conducted through air which is
sparking. Sparking deteriorates the comm. or slip ring to a rougher surface finish, it also
makes both the brush and the commutator wear faster. If possible get profiles of each
commutator in as many paths as possible. If TIR is more than .003” this may not be a good
choice for a brush test since brush life is never very good at this degree of roughness.
One also needs to make sure the springs and brush holders are in good condition. Dirty,
fatigued or sluggish springs and pitted brush holder surfaces will not allow the brush to be
fast acting so it can intimately follow the never perfect commutator surface. Remember, a
1200 RPM machine revolves 20 times every second. Even a comm. with .003 inches of TIR
( total indicator runout ) must have the team effort of the brush, spring and brush holder to
allow it to quickly move in and out .003 inches with every revolution and not have sparking.
Measuring all brushes prior to the test is probably not necessary but recording the lengths of
all brushes in one conveniently located positive and negative arm or stud should suffice.
Numbering these brushes with a metallic marker will help make accurate recording of data
with future measurements easier. These measurements should be made with a dial caliper
in thousandths of an inch rather than 16ths of an inch with a ruler. If more than one motor is
involved in the field test, it’s best to make sure that each measured and labeled brush has a
unique number to avoid mix-ups when recording the field test data. In other words, do not use
brush number 1 to 12 for one motor and number 1 to 12 on another sister motor. Numbers 1
to 12 & 13 to 24 or 1A to 12A & 1B to 12B would be better choices,
The brush test should be run for at least 2,000 operational hours. For a machine running 24 /
7, that works out to about 12 weeks. The test should also allow at least 2 inspections after
the initial installation. These future inspections should be agreed upon before the test even
starts. Selecting the machine to test on, installation and inspections should be made with
the brush companies representative present. Filling in the attached Motor Inspection Form
will also help document the test conditions or environment.. Entering data into the wear
spreadsheet will allow automatic calculation of the brush life.
If at all possible, you should also use a depth micrometer to measure the depth of the brush
paths at the various inspection dates. This is valuable information to also compare
commutator or slip ring WEAR and not just brush wear. Make these entries in the comment
section of the wear spreadsheet.
Field test are expensive and time consuming, so every effort should be taken to insure
complete and accurate data is collected.
Please allow me to help you, in your efforts to obtain a meaningful comparison.
Gary E. Lozowski
Segment Manager-Mining
Ph 864 458 7777 Ext 107
Cell 864 915 5894
[email protected]

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How Should a Brush Test be Performed ?

Selecting a motor or generator with a reasonably smooth commutator surface is also

Please allow me to help you, in your efforts to obtain a meaningful comparison.

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