Welcome All Delegates From

North East India

9th Feb 2010

Introduction

D Basak General Manager Sales & Marketing Raktim Baruah Manager Marketing

A R Dutta Regional Manager East Zone

M Agarwal (M/s Aradhana)Customer Relation Partner

Contents
Group Overview Carbone Lorraine India Electrical Carbon Division Products and Services Brush Holders, Slip Rings & Signal Transfer System Value Added Services Carbon Brush

Technical Aspects
Grade Selection Criterion Brush Face Interpretation Commutator Face Interpretation Most Common Problems Preventive Maintenance Your Questions

Group Overview

1892- Foundation of CGE de Nancy and Le Carbone 1937- Merger of CGE and Le Carbone to form Carbone Lorraine 1991 - Stackpole acquisitions (USA, Canada) 1985 - Controlling stake in Ferraz (France, USA, Japan)

1995 - Carbone Lorraine India & JV with Elca

2001 - 100% acquisition of Elca Carbone Lorraine.

Industrial operations extending to 40 countries

Carbone Lorraine Company driven by excellence

World #1 in brushes for electric motors World #1 in graphite anticorrosion equipment for the chemicals and pharmaceuticals industries World #1 in fuses for power semiconductors

World #2 in industrial fuses

World #2 in isostatic graphite production

India # 1 in Brushes for electrical motors

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Carbone Lorraine India

Divisions

Electrical Application Division - Bangalore

High Temperature Division- Bangalore

Ferraz Shawmut Division- Bangalore

Chemical Equipment Division- Chennai

Carbone Lorraine sites

Electrical Application Division

GRAPHITE - Amiens, France Boonton, USA Bangalore, India St Marys, USA Frankfurt, Germany

METAL - Hittisau, Austria - Jestettan, Germany - Amiens, France - Sau Paulo, Brazil - Milan, Italy - Bangalore, India

- Shanghai, China

Carbone Lorraine India

Electrical Application Division

140 Employees

Quality Circle Excellence Award, 2009

ISO9000- 2000 by BVQI

Carbone Lorraine India

Electrical Application Division

Electrical Carbon Division Products & Services Carbon Brush

Machinery maintenance tools

Brush Holder Slip Ring

Sliding Contact

Specialised maintenance service

Signal Transfer System

Carbone Lorraine India

Electrical Application Division

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Capacity
150 TPY of Carbon blocks
50000 Traction Brushes per month 50000 Industrial Brushes per month 300000 Railway Carriage Fan Brushes per month 1000 Metallised Panto-strips per month 300 Slip Ring Assembly per month 5000 Brush Holder Assembly per month

Carbone Lorraine India

Electrical Application Division

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and many more And many more valued customers

Carbone Lorraine India

Electrical Application Division

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Major Power Plants we serve in India NTPC TATA POWER GSEB

ASEB
NPCIL DVC WBSEB WBPDCL MAHAGENCO TNEB PSEB

NEYVELI
UPSEB TORRENT OSEB BPSCL KPCL DPL APGENCO
and many more . . . .

HSEB
RSEB ESSAR POWER CEYLON EB SALCON PHILLIPINES INDONESIA POWER VIETNAM HYDRO SUZLON

Carbone Lorraine India

Electrical Application Division

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Carbone Lorraine India

Electrical Application Division

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Rush line
We have special line to produce urgent orders/ small quantities and orders from distant customers Export North East India Upper Northern India Make the brushes in 48 to 72 hours

Logistic arrangement to deliver the brushes in 72 hours

Carbone Lorraine India

Electrical Application Division

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Carbone Lorraine India

Electrical Application Division

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Carbone Lorraine India

Electrical Application Division

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BRUSH HOLDER

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Importance of Brush Holder

Stability of Brush Uniform contact of Brush to the Commutator/ Slip ring Constant Spring Force for the entire Brush Length. Sturdiness of the Design Good heat discharge Uniform sliding of the carbon brush Parallelism of the Brush Pocket Anti-erosion coating

20

CONSTANT FORCE HOLDERS

Force-Displacement characteristics C.F. springs Vs Conventional springs

Spring Pressure (or Force)

21

Optimum Force

C.F. Spring

Clock or Helical Spring (Spring Displacement) New Brush Length Fully Worn

CL spring

BRUSH HOLDER MANUFACTURING STATE OF ART TECHNOLOGY

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DESIGN & DEVELOPMENT

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DESIGN & DEVELOPMENT

GRAVITY DIE CASTING METHOD
Better process than Sand Casting High Dimensional Accuracy Better surface finish Better Mechanical properties No blow holes

Longer life

GEOMETRY TESTS

FEW SLIPRINGS / BRUSH HOLDERS FOR HYDRO, THERMAL, RAILWAYS

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TM 165/GE752

GENERATOR VA TECH HYDRO

TM HITACHI BH

EXCITOR
SIEMENS WESTINGHOUSE

COMMONLY USED BRUSH HOLDERS FOR LOCOMOTIVES

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Auxiliary Generator

Traction Motor

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DESIGN & DEVELOPMENT

Brush Holder for Slip Ring generator

On Line Brush Gear Assembly Brush Holder for Hydel Exciter

ADVNACED DESIGN FOR POWER PLANT BH ONLINE BRUSH GEAR ASSEMBLY PLUG TYPE

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Slip ring, Brush Rocker, Brush Holder, Brush for Hydro Generator

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30

SOME MORE BRUSH HOLDER

Check your Brush Holder.

Brush Holder Condition.

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Height to Commutator/ Ring - 2 - 3mm Clearance to Brush - 0.05 - 0.25mm Spring Pressure & Condition Stagger if applicable Spring Arm Position on Brush Brush Arm Position (neutral )

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What a Brush is experiencing

Running at a peripheral speed of 50m/s (i.e 180 Km/Hr)

So what is required for a brush to perform ? Answer lies in Preventive Maintenance

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PREVENTIVE MAINTENANCE

Commutator Condition.
TIR less than 0.05mm (0.01 new) MBTB less than 0.008mm Bar edge chamfer Undercuts clean no side mica Fine turned finish with no glaze
(0.003 new

Slots parallel throughout to riser.

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CL Profiler
The ideal solution for proofing commutators and slip-rings

Instant reading of TIR (ovality) User friendly Windows based software to analyze the data Resolution +/- 1 m

35

BRUSH SPRING PRESSURE

IDEAL SPRING PRESSURE FOR COMMUTATOR = 1.8 ~ 2.3 Kg / Cm2 IDEAL SPRING PRESSURE FOR SLIPRING = 2.0 ~ 3.0 Kg / Cm2

36

Grinding stones for commutator or slip rings

Sandpaper only cleans a flat spot Commstones Remove it!

Grains: Coarse, Medium, Fine Usage: Roughness surface finishing after grinding

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PREVENTIVE MAINTENANCE OUR VALUE ADDED SERVICES

THE CL TOUCH

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VALUE ADDED SERVICE WE OFFER

We have a trained team to provide the following value added services

Diagnostics & Health Report Profile of the Commutator (TIR, MBTB, Raised Mica)
Surface Roughness Spring Pressure Commutator & Brush Study Report with recommendations

In-Situ Commutator Turning

In-situ Mica Undercutting/Beveling/ Chamfering In-situ Commutator Grinding Brush Holder Adjustments Neutral Axis adjustments

OUR VALUED ADDED SERVICES TO ESSAR STEEL

In Situ Turning of 6000 HP Westing House make Roughing Mill DC Motor Essar Steel

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Motor before turning

In situ turning with tool

After Service

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BRUSH BEDDING

Gives the contact surface of brush the exact curvature of the commutator. Gives good mechanical and electrical contact to the brush. Can be done by using yellow sand paper (medium grain) or by using bedding stones.

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THE CARBON

COAL

DIAMOND

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History
Approx 1870 Copper Brush Until about 1890, bunched copper wire brushes were used.

Professor George Forbes, from his work as a manager of the British Electric Light Company involving carbon products and dynamo development, was granted a patent No.1288 in 1885

But the best documented is of its use on a tramcar in Richmond Va. USA , of the Thomson-Houston Company, the forerunner of GE

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Why carbon ?
Few Unique properties of Carbon makes it right material for electrical sliding contacts Good electrical Conductivity Good thermal conductivity Can accommodate current reversal

Low shear strength of graphite crystal

Good Lubrication Properties Low modulus of elasticity No melting point, Solid up to 3500C Low Thermal Expansion (friction and wear)

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CARBON BRUSH MANUFACTURING PROCESS

+ +
Graphite + Coke

BINDERS

+ +

ADDITIVES

GRINDING

PRESSING

BLENDING

MIXING

BAKING

GRAPHTISING

IMPREGNATION

Brush

Brush

Plate

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Block Grades
Electrographite Metal Graphite

Soft Graphite
Carbographite Bakelite Graphite

Grades Portfolio of CL
Electro-graphite
EG353, EG326, EG359, EG359MX, EG359MD, EG366, EG388, EG98, EG300, EG34D,EG389P, EG367, EG321, EG369, EG332, EG319P, EG9049, EG8220,EG6754, 2192, CB386 ..

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Metal Graphite
MC84Z1, MC70, MC80Z3, BE14M( Lead Free), CG650, CG652, CG626, AE50, OMC, MC79P ..

Soft Graphite Carbo-graphite Silver Graphite

(LFC554, LFC557, EG5U )

(L16(I), A261M, L53(i), L52(I),. )

(BG440, BG446, BG563) AG20, CA35, CA38, CA10..)

Bakelite Graphite

47

GRADES FOR POWER PLANTS

THERMAL, NUCLEAR, HYDRO AND WIND ENERGY

FOR GENERATORS

LFC554, CG626

FOR EXCITORS :

EG313, EG34D, EG353

:

FOR SHAFT EARTHING

EG5U + AG20

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Our Grades vis--vis Competition Grades

4000 3500 3000 2500 2000 1500 1000 500 0 LFC554 EXISTING COMPETITION

Micrograph

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LFC554 - ADVANTAGES

LIFE OF MORE THAN 3000 HRS. LOW WEAR OF SLIP RING LOW FRICTION CO EFFICIENT SPEED UPTO 100 m/s GOOD SHOCK ABSORBER LOW LOSSES GOOD MECHANICAL CHARACTERISTIC GOOD CURRENT DISTRIBUTION LIFETIME 15% ~ 30% MORE GOOD RESPECT OF RING LOW CONTACT DROP

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LFC554 - APPROVALS

BHEL ALSTOM ABB SIEMENS ELECTROSILA GE ANSALDO

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Some technical aspects on Carbon Brush

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How Much Brush Pressure ?

53

Brush Wear Spring Pressure

Optimum pressure range

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Impregnation

Improves Brush Life Improves Filming Provides Low Humidity Protection Allow High Temp Operation

Reduces Copper Drag Contaminated Atmospheres Minimizes Commutator Wear Reduces Friction

Electrographites
Untreated Treated
Wear Rate Brush Temperature

(Increasing) (Decreasing)

Humidity

55

GRADE SELECTION CRTITERION

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POINTS

Patina (film) formation Commutator Condition Rideability Operating Temperature Atmospheric Condition

57

Patina

Commutator Ovality Detoriates with Km Run

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Brush wear rate vs. Temperature

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BRUSH WEAR DUE TO CONTAMINATION

Silicon Unusual Brush Wear Silicon comes - Varnish or insulation, Sealants, Armature bands slot insulators, Wedges, Impregnated tape etc.

Grease & Oil Very high brush wear (5/6 times) Due to leakage, defective bearings, excessive greasing etc

Corrosive Gas & Dust High brush wear, affect the metal components like flexible, terminal, Copper of the Commutator or Slip rings Abrasive dust caused grooving in copper collector Comes from surrounding environment

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Brush Face (Contact Face) Interpretation

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Brush Face (Contact Face) Interpretation S1 Dense, shining sliding face. S3 Slight porous sliding face

Normal Operation.

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Brush Face (Contact Face) Interpretation

S5 Fine Hairlining

S7 Hair-lining

S9 Tracking with hair lining and grooves

slight dust influence

Under-loaded, influence of dust or grease

Stronger Underload and influence of dust or grease

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Brush Face (Contact Face) Interpretation S11 Ghost-marks, difficult commutation

Commutation problems, e.g. false or incorrect position of the neutral zone or interpole.

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Brush Face (Contact Face) Interpretation

S13 Burning edge of the leaving or trailing edge

S15 Eroded brush face

Difficult commutation, heavy sparking, interruption of contact due to out of round of commutator or insufficient brush holder spring pressure, excessive current.

Electrical overload, interruption of contact

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Brush Face (Contact Face) Interpretation

S17 Lamination of sliding face.

S19 Double facing here for a twin brush

Burned segments of the sliding face caused by a winding fault giving voltage surge during commutation.

Tilting of the brush in dual direction machine

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Brush Face (Contact Face) Interpretation

S21 Copper nests

S23 Chipped edges

Pick up of copper particles, often following copper drag

High raised lamination, commutator seriously out of round, brush chatter by low load and idle running.

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Commutator Surface (Patina) Interpretation

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Commutator Surface (Patina) Interpretation

Normal Operation

P2

P4

P6

P2 - P4 - P6: show normal skins. Colour intensity Uniform, light maroon (P2) to darker maroon P6). The machine and brushes working well.

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Commutator Surface (Patina) Interpretation Badly Formed Patina

P12: Streaky skin. Lines and bands of varying size alternately light and darker without wear of the copper. Most frequent cause: excessive humidity, oil vapours and aggressive gases in the atmosphere under loaded brushes.

P14 Torn patina General appearance as in P12, but with narrower tracks and commutator wear As in P12, but the conditions have been maintained for a longer period causing commutator damage

P16: Patchy skin. Of blotchy appearance having irregular and diverse colorations and dimensions without character of symmetry. Commutator deformed or dirty.

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Commutator Surface (Patina) Interpretation Patchiness due to mechanical causes

P22: Isolated or regularly distributed blotches. Dark blotches having blurred boundaries. Out of round commutator, vibrations of the motor caused by badly adjusted shaft or damaged bearings

P24: Dark blotches with sharp or irregular edges followed by lighter areas in alternating fashion with gradual reducing intensity of colour. Raised segment or group of segments causing the brush to bounce.

P26 - P28: Bars marked at their centre or at their edges. Shading at the centre of the bar or fringe marking at the edges. Defective maintenance of commutator, poorly turned or trued

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Commutator Surface (Patina) Interpretation Bar marking due to electrical causes

P42: Alternate bars light and dark. Uneven current distribution over two parallel windings caused by double windings crossing in the same slot

P46: Marking at double pole pitch. Usually by faulty soldering of the risers or segment connections

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Commutator Surface (Patina) Interpretation Burning

B2

B6

B8 B8: Metallic erosion (burning) at centre of bars

B2 - B6: Metallic erosion, burning and dark patches at edge of bar due to the degree of sparking.

Sparking caused by commutation problems

B10: Pitted skin. Small clear, light spots of variable number and random distribution over a normal skin. Patina destruction caused by too large electrical resistance/ sparking under the brushes.

B10

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Commutator Surface (Patina) Interpretation Bar Marking

T10 Appearance: Dark patches at edge of bars in direction of rotation Long periods with the motor being stationary without power or short stationary periods under load

T12 Appearance: Burning of a trailing edge and the next leading edge of a bar Caused by protruding segment as in L2

T14 Appearance: Dark markings Sign of a low segment, could also be caused by a flat spot on the commutator

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Commutator Surface (Patina) Interpretation Bar Marking

T16 Clearly defined dark markings together with segment edges burnt Raised mica

T18 Dark markings Badly undercut segment edges

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L - COMMUTATOR BAR FAULTS

L 2: High bar.

L 4: Low bar.
L 6: High micas. L 8: Copper fins. L 10: Copper drag.

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A BRUSH

Definition A brush is an electrical conductor subject to friction: therefore, it is a mechanical and electrical device that has the function of transferring a current, that may be very variable, between the rotating part of a machine and its fixed external power supply or load circuit.

A Carbon Brush should have moderate wear of the brush and respect for the commutator

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BRUSH FLEXIBLE CONNECTIONS

TAMPING METHOD (Automatic) Drilling, Roughing, Ramming Low Electrical Resistance High Mechanical Resistance General ruleDrill depth = 5 (=diameter of flex)

Tamping Machine Pull Out Strength

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THE MOST COMMON PROBLEMS

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BRUSH SPARKING
CAUSES ELECTRICAL : Bad Commutation (neutral shift) , wrong grade , Low Spring Load

MECHANICAL :
Friction, vibration, deformed commutator, High Spring Load

EFFECTS
BRUSH WEAR RATE INCREASES COMMUTATOR DAMAGE BY BURNING OF METAL REMEDY: Right Grade, uniform spring load, good commutator, adjust neutral, tight connections, clean holders & metals

81

PIGTAIL FAILURE
CAUSES ELECTRICAL : Insufficient size, High electrical resistance, Improper connection

Overload (high current), Environment

MECHANICAL : Vibration, Oversize, High Spring Load, Improper connection, Commutator ovality, Brush sticking inside holder, Flexible touching the spring. EFFECTS BRUSH WEAR, FLASHOVER COMMUTATOR DAMAGE REMEDY: Uniform spring pressure, free movement in brush holder, strong connection, Reinforced flexible, Tinned flexible.

82

BRUSH BREAKAGE
CAUSES
ELECTRICAL : Under-load conditions, Overload conditions, Poor Patina, low spring load MECHANICAL :

Vibration, High Spring Load, deformed commutator, high speed, brush chatter, Friction
EFFECTS PRODUCTION LOSS

COMMUTATOR DAMAGE REMEDY:

Use a grade suitable to load cycle , Adjust spring pressure, Control vibration, turn commutator within limits, suitable clearance between brush and brush holder & commutator, preventive maintenance

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Preventive Maintenance

84

PREVENTIVE MAINTENANCE
CHECKS DURING SLOWING DOWN

Vibration & Noises

Beating in the couplings

Temperature of the Commutator

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PREVENTIVE MAINTENANCE
CLEANING

Blow dry compressed air from both ends of the machine

Clean the filters with a solvent Wipe all insulators with a dry rag Clean between the commutator bars with a glass fibre stick.

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PREVENTIVE MAINTENANCE
MEASUREMENTS / INSPECTIONS

Concentricity of the commutator Spring pressure of the holders Length of all brushes in one arm

87

PREVENTIVE MAINTENANCE
CHECK BEFORE STARTING UP
Examine the bar chamfers Check for any oil leakage / grease on the commutator No carbon dust deposited on brush holders

The interior of the brush holders

Brush flexible are not oxidized. Not pinched by the pressure finger Brush sliding normally inside the holder. Pressure fingers in correct position

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PREVENTIVE MAINTENANCE

Brushes Do & Dont

Do not mix two or more grades on the same machine Allow brushes move freely in their holders without excessive clearance Make sure to eliminate the remaining skin before changing the brush grade. Brushes are not wrongly mounted (Beveled brush) Holder Pressure Finger is properly placed on Brush Top

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MOVING FORWARD

with our quality of products

with our quality of services with our quality of commitments

CARBONE LORRAINE INDIA

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Cordially Invited To Visit Us

BANGALORE : DEBASISH BASAK (Mobile : 9900950430) email- d.basak@carbonelorraine.com RAKTIM BARUAH FRONT OFFICE : KOLKATA: A R DUTTA (Mobile : 9831084421) email elcacal@cal3.vsnl.net.in / ar.dutta@carbonelorraine.com (Mobile :9845692862) email - raktim.baruah@carbonelorraine.com Ph:080-30946121/2/3/4/5 / Fax :080-27831746 in.be.marketing@carbonelorraine.com

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Your ?

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THANK YOU

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Non-uniform brush wear

Why do brushes show a non-uniform brush wear on a particular machine ?
Non-uniform out-of-roundness from one brush track to the next Non-uniform brush pressure Non-homogenous properties of Carbon Non-uniform total down-force Non-uniform characteristics of the spring pressure with the brush wear Variable friction in the brush box Differences in temperature Non-uniform current distribution Non-uniform commutation Stability of the brush holders and brush stud assembly Differential polarity Non-uniform brush spacing ( pole pitch) Non-uniform brush seating Non-uniform film formation

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How important is brush hardness?

There is no correlation of hardness and wear. (ref IS:9919)

The wear rate of carbon brushes is determined by various surrounding effects and the electrical and mechanical stability of the contact points
Cleaning and polishing action is also not determined by the hardness of a material. Commutator attack is not affected by "hard" materials, but by the ambient conditions, uneven current distribution or electrical overload.

98

Brush Holders

Modern day brush holders for large and medium size machines are usually manufactured from precision cast Leaded Gun Metal, Gravity or Pressure Die Cast Aluminum, Permacast, or Investment Castings. Some Brush Holders are manufactured from Brass extrusions and some fabricated from brass strip. Occasionally we come across machines with moulded Brush holders with strip inserts for the brush to slide up and down against. All have to be able to withstand the rigors of service and extreme temperature gradients without distortion. All have to conform to International Standards such as IEC136 for dimensional accuracy.

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How important is brush hardness?

There is no correlation of hardness and wear. The wear rate of carbon brushes or other carbon contacts like carbon strips is determined by various surrounding effects and the electrical and mechanical stability of the contact points in the contact surface of brush and current collectors. A "soft" carbon brush grade , gives a much better performance e.g. on large mill or fast running machines than "hard" brush grades. Cleaning and polishing action is also not determined by the hardness of a material. The ingredients of the material do have a much bigger influence.

Commutator attack is not affected by "hard" materials, but by the ambient conditions, uneven current distribution or electrical overload.

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Brush holder mounting & construction

Clearance 2.0 3.0mm Angle to commutator or slipring Alignment on the brush arm

Rigid to avoid vibration & resonances Large surface area to provide good heat dissipation Stable brush support
Flat support face Mounted close to running surface

Adjustable pressure and position on support arm

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Brush Holder Springs

There are three main types of spring used today in brush holders.
The Constant Force Spring The Clock or Coil Spring The Tension Helical Coil Spring

Material used vary widely:- Stainless Steel, DGS, Phosphor Bronze. Some of the DGS are Zinc Plated & Passivated or Cadmium Plated & Passivated

Spring pressure is very crucial to the brush life, commutator condition and life of the spring.
Spring Pressure ranges from approx. 120gm/cm2 (approx 2
PSI) to 700gm/cm2 (approx 10 PSI).

102

Brush Holder Spacing

2-3mm

Only on rather small or very large motors is the recommended gap beyond this range. This gap is not always adjustable on newer motor designs. Readjusting this gap should only be necessary after turning or stoning a substantial amount of the commutator or slip ring diameter. Slip ring motors typically have a 3mm maximum gap.

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Brush Holder Alignment

Brush holder alignment ok, exactly perpendicular to the slip ring or commutator surface

Commutator or slip ring

Rotation

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Brush Holder Alignment

Brush Holder alignment , not the best, but 1 or 2 degrees trailing is OK

Commutator or slip ring

Rotation

105

Brush Holder Alignment

Brush Holder alignment needs adjustment. This is called leading or stubbing and can cause fast wear or friction chatter. Just 1 or 2 degrees makes a big difference.
Commutator or slip ring

Rotation

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Brush Spacing

All X dimensions should be equal.

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The Checks

Profile It should not exceed 0.03 mm in one revolution. The value is measured using a profile meter.

Deformation This measurement allows to study the deformation on commutator or slip rings. We can also measure the depth of wear on brush tracks to determine what type of tool is best adapted to the rectification.

Brush-holder spring pressure We use a probe between the pressure system and the carbon brush to measure the spring pressure. This is essential to detect any deviation from our recommended pressure

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The Checks

Dynamic control of the neutral Incorrect alignment of the neutral will lead bad operation and cause sparking.

Surface roughness We must avoid peaks (Ra) less than 0.2 mm because it creates mechanical instability and can cause vibration. A low roughness reduces the number of points of contact between the carbon brush and the commutator or slip rings. We use a roughness meter to measure the surface roughness

109

CONTACT DROP

Brushes are sliding contacts

The PATINA is a mixture of metallic oxides, carbon and water The interface layer is composed of a gaseous film, ionized with particles of carbon in suspension and sometimes of fine dust. Contact drop is influenced by all the factors which may modify the patina or the interface layer. For example, the temperature, the pressure and the ambient humidity, the atmospheric impurities, the speed of the commutator, the pressure applied on the brushes, the transverse currents and the nature of the brush itself. Contact drop gives rise to electrical losses and heating of the commutator or ring occasioned there by and influences commutation and the distribution of current between brushes.

DISTRIBUTION OF CURRENT IN THE BRUSHES

The current is not distributed uniformly across the whole of the contacts surface of the brush. In fact, it passes through a variable number of zones of comparatively very small surface area. The collecting zones are constantly changing with time, and if everything goes well, they move to engage all parts of the contact surface equally It may happen that this equilibrium is interrupted. The areas of current passage are regrouped and diminish in number. Lining or threading appears on the skin developing more clearly as the passage of current becomes more localized under the brush. Brush points of contact interface layer skin metal

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.The causes of these phenomena are very diverse: External agents (dust, gas, excessive humidity, low temperature). Grade of brush not suitable for the running conditions of the machine (skin too thick, current density too high or too low, ventilation, etc.). By an identical process, the current may be unequally distributed between brushes on the same arm on a commutator or along the same track on a ring. Considerable difference of brush pressure from one brush to another is often the origin of this fault.

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RESISTIVITY IN BRUSH DESIGN

There is no strict relationship between the electrical Resistivity of a brush and its contact drop, especially when impregnated brushes are involved Generally, Resistivity modifies only very little the electrical losses of the brush. For laminated brush materials the Resistivity values will be noticeably different if they are measured parallel or perpendicularly to the cleavage planes. In order to take advantage of this property (reducing circulating currents), it is necessary for the brush lamination to be parallel to the commutator bars. The split brush and even more the sandwich brush permits an artificial increase in the transverse resistance

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CHARACTERISTICS OF CARBON

Specific Resistance Current Density Flexural (Transverse) Strength Contact Voltage Drop Co efficient of Friction Hardness

113

What we expect a Brush to Do

Transfer Current.

Remain in Contact with the rotating surface

Give a good life Not to damage the surface in contact No Sparking

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Patina
Constriction resistance many times greater than resistivity Very small actual contact area though it may appear large

Presence of patina or oxide/ash layer reduces the conducting area

Friction is concentrated at the high points resulting in very high localised temperatures

Air film separating surfaces Arc conduction between separated surfaces

Carbon Sources
Organic Material
Heat in the absence of Air

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Carbon
Carbon Black
Petroleum Coke Foundry Coke Artificial Graphite Natural Graphite

Oil / Gas
Petroleum Coal Coke Nature

Binders

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Pitch Tar Resins Metals

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Others

Copper Silver Additives

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Baking

Carbonises Organic Binder

Removes Volatile Initiates preliminary shrinkage

Graphitisation

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Makes disordered Carbon more Graphitic

Removes Impurities
Alters Material Properties

120

Silicone
Silicones adversely effects on the performance of brushes .
Symptoms - Very high rate of brush wear occurs, which can reach or exceed 10 to 15 times normal. Where from Silicon comes Varnish or insulation, Sealants, Armature bands slot insulators, Wedges, Impregnated tape etc. are less stable after polymerization

What helps heavy wear Restricted volume of air to the machine High internal temp on the commutator (or ring) High current through the brushes
Causes Products of hot distillation of the silicones brings unusual brush wear Condensation on the commutator (or the rings) forming an insulation film which disturbs the passage of the current and causes arcs or sparking underneath the brushes. Decomposition of silicone vapour under sparking conditions with the formation of SiO2, which is a very abrasive agent for the brushes
Note: All silicone brush tops and insulation sleeves are temperature cured to remove volatile silicone compounds.

121

Oil & Grease

Oil & Grease also adversely effects on the performance of brushes .
Symptoms Very high rate of brush wear occurs, which can reach or exceed 5 to 10 times normal. Also damage the commutator or sliprings by grooving lines. Where from they come Due to leakage, defective bearings, excessive greasing etc. What helps heavy wearThe oils or greases have a very low boiling point. Restricted volume of air to the machine High internal temp on the commutator (or ring) High current through the brushes Causes Products of hot distillation of the oils which bring about the unusual brush wear Forming an insulation film due to condensation on the commutator (rings) - disturbs current transmission and causes arcs or sparking underneath the brushes. Decomposition of oil vapour under sparking form oil-coke, which is hard, abrasive agent. Note - Full load machines are more adversely affected than under load machines. Effect of very small vapour on full load is much more than quite high oil vapour on no load running periods.

122

Contamination in Atmosphere
Corrosive Gases also adversely effects on the performance of brushes .
Symptoms Very high rate of brush wear. Damages the commutator or sliprings copper. Damages the Carbon brush Flexible & Metal top copper. Blackening of flexes can lead to stiffening and premature failure

Types & Causes

Sulphur Compounds Sulphur dioxide , Hydrogen sulphide Commutator & flexible reacts with the sulphur and can form a non-conductive film resulting in damage to brushes and commutator. Increases friction causing chatter and increased commutator wear
Chlorine Used in bleaching Reacts with the commutator & flexible with same effects as Sulfur

Acids Used in cleaning (Pickling line etc.) Reacts with the commutator & flexible with same effects as Sulfur
Plastics Non-conductive film, poor commutation and brush wear Note Brushes are designed with tinned copper Flexible and tinned plated Terminals & Pressure plate.

Carbone Lorraine India

Application Electrical Division

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BSP Plant wise details

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A261 against 4T

Problem faced by BSP Supply of brushes in 4T or EG202D grade Proposed Trial with our Grade A261M against Drg no. BRUSH-4 (our drg CL57DC02), brush size 55x32x10mm at Merchant Mill, BSP Our brushes in grade A261M fitted on 6D motor at M. Mill on 13.04.09 Trial was successfully completed on

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EG359 against EG236S

Problem faced by BSP Fast wearing of EG236S (45 days) Proposed Trial with our Grade A261M against Drg no. BRUSH-4 (our drg CL57DC02), brush size 55x32x10mm at Merchant Mill, BSP Our brushes in grade EG359 were fitted on BHEL motor at WRM on Trial was successfully completed on with the stable patina and brush life of ____ days

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Grade Proposed for Trial

Oxygen Plant Application Existing Grade BBM Plant Application Existing Grade Rail Mill Plant Application Our grade Our grade -

Existing Grade -

Our grade -

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Excessive vibration caused by deformed commutator, low commutator temperature, or low spring pressure