Brush holders provide stable support and proper positioning for the carbon brush, and they apply force to the carbon brush creating a stable sliding electrical contact.
However, a misaligned brush holder is usually a consequence of the way the brush holder attaches to the bracket or is a result of accidental damage to individual brush holders or the brush holder brackets. As a result, a brush holder that is no longer parallel to other brush holders or commutator bars may incur unequal loading resulting in poor commutation and damage to the commutator surface.
Under today’s reduced maintenance and current operating conditions, the need to replace brush holders tends to occur after a machine failure.
But what happens when the original holder is no longer made, or the current design failed too soon?
That’s where Helwig Carbon’s world-renowned engineering team comes in.
From Concept Drawing to Show and Tell Samples
The Helwig team focuses on your specific operational problems to provide the best brush holder solution for your needs.
First, we look at a sample of the existing holder and the full nameplate information from the motor. Using photos of your existing application with the existing brush gear, we review:
- Supplied measurements of the diameter of the commutator or ring
- Number of holders and brushes
- Brush size and bevel
- Brush holder bottom bevel
- Terminal size and style
- Mounting bolt diameter and length
- Distance from the commutator or ring to the nearest obstruction
Our engineers analyze the issues. Once the pain points are identified, Helwig Carbon creates a drawing and model of the solutions, and our experienced 3D printing staff then print the sample holder within a few hours.
Next we ship an approval sample to you for confirmation that the part meets your application’s brush holder requirements.
If anything is out of alignment, we can easily make any adjustments to match your real-world application, ensuring you get the right part for the job. All of this is done before any resources are committed to manufacturing the final product—saving you time and money and reducing the risk of failure.
Helwig Carbon can custom engineer any holder to your project’s specifications. We provide many options to ensure the proper fit and function of your brush holders using our skilled staff and 3D printing applications to get the right fit every time.
From banks of holders to single brush boxes, virtually all sizes of industrial brush holders are available, including small holders for special applications.
Whether your current design is breaking springs, has short brush life or is causing damage to your commutator or rings, or after a flashover happens, Helwig Carbon provides the solutions from concept design to printed part within days.
Are Custom Brush Holders Right for Your Project?
Helwig Carbon will help you find the right custom brush holders for your unique project. For more information or to request a quote, contact us.