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8 in (203 mm) wire brush mounted to a bench grinder. The wire brush is primarily an abrasive implement, used for cleaning rust and removing paint. It is also used to clean surfaces and to create a better conductive area for attaching electrical connections, such as those between car battery posts and their connectors, should they accumulate a build-up of grime and dirt.
The brush compound is compacted in a tool consisting of upper and lower punch and die, on mechanical or hydraulic presses. In this step, depending on later processing, the copper wire (called shunt wire) can be inserted automatically through a hole in the upper punch and fixed into the pressed brush block by the powder pressed around.
As the copper brushes wore away, the dust and pieces of the brush could wedge between commutator segments, shorting them and reducing the efficiency of the device. Fine copper wire mesh or gauze provided better surface contact with less segment wear, but gauze brushes were more expensive than strip or wire copper brushes.
Coils are typically wound with enamelled copper wire, sometimes termed magnet wire. The winding material must have a low resistance, to reduce the power consumed by the field coil, but more importantly to reduce the waste heat produced by resistive heating. Excess heat in the windings is a common cause of failure.
The large brown molded-plastic piece in the foreground supports the brush guides and brushes (both sides), as well as the front motor bearing. The universal motor is a type of electric motor that can operate on either AC or DC power and uses an electromagnet as its stator to create its magnetic field. [ 1 ]
The brushes of a generator must be set in the neutral plane; that is, they must contact segments of the commutator that are connected to armature coils having no induced emf. If the brushes were contacting commutator segments outside the neutral plane, they would short-circuit "live" coils and cause arcing and loss of power.
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