Main performance parameters of carbon brush leads
As a key component connecting carbon brushes and external circuits, the performance parameters of carbon brush leads directly affect the stability of current transmission and the overall operating efficiency of the equipment, mainly including the following categories:
1、 Electrical performance parameters
Conductivity: With resistivity as the core indicator, it reflects the degree of obstruction of current passing through the lead wire. The resistivity of leads made of different materials varies significantly. For example, copper leads have lower resistivity, which can reduce energy loss during current transmission and is suitable for high current scenarios; Although some alloy material leads have slightly higher resistivity, they can maintain stable conductivity in specific environments.
Rated current: refers to the maximum current value that the lead wire can withstand for long-term safe operation. Beyond this value, the insulation layer of the lead may age or the wire may melt due to overheating, and it is necessary to match it reasonably according to the working current of the motor where the carbon brush is located.
2、 Mechanical performance parameters
Flexibility: measures the fatigue resistance of a lead under bending and vibration environments. Motors often experience vibration during operation, and flexible leads can reduce the risk of breakage. For example, leads made by twisting multiple strands of thin copper wire are easier to adapt to frequent deformations than single strands of thick wire.
Tensile strength: Refers to the ability of a lead to withstand tensile force without being pulled apart. During installation and use, the leads may be subjected to certain tensile forces, and sufficient tensile strength can prevent wire breakage faults.
3、 Environmental adaptability performance parameters
Temperature resistance: including the ability to withstand high and low temperatures. When the motor is running, the friction between the carbon brush and the shaft will generate heat. In high-temperature environments, the insulation layer of the lead wire needs to be stable, not melted, and not aged; In low-temperature environments, the lead material should not crack due to embrittlement, ensuring normal operation in different climates or working conditions.
Corrosion resistance: For working environments that are humid, dusty, or contain chemical gases, the surface coating or insulation material of the lead must have corrosion resistance to prevent a decrease in conductivity or structural damage caused by corrosion.
4、 Insulation performance parameters
Mainly manifested in insulation resistance and voltage resistance. The insulation layer should effectively isolate the wire from external metal components to avoid leakage or short circuit. The higher the insulation resistance, the smaller the leakage current; The ability to withstand voltage ensures that the insulation layer is not broken down at a certain voltage, ensuring the safety of equipment and personnel.
These performance parameters are interrelated and need to be comprehensively considered based on the application scenarios of carbon brushes, such as industrial motors, new energy vehicle motors, wind turbines, etc., in order to achieve efficient matching of leads, carbon brushes, and the entire motor system.
1、 Electrical performance parameters
Conductivity: With resistivity as the core indicator, it reflects the degree of obstruction of current passing through the lead wire. The resistivity of leads made of different materials varies significantly. For example, copper leads have lower resistivity, which can reduce energy loss during current transmission and is suitable for high current scenarios; Although some alloy material leads have slightly higher resistivity, they can maintain stable conductivity in specific environments.
Rated current: refers to the maximum current value that the lead wire can withstand for long-term safe operation. Beyond this value, the insulation layer of the lead may age or the wire may melt due to overheating, and it is necessary to match it reasonably according to the working current of the motor where the carbon brush is located.
2、 Mechanical performance parameters
Flexibility: measures the fatigue resistance of a lead under bending and vibration environments. Motors often experience vibration during operation, and flexible leads can reduce the risk of breakage. For example, leads made by twisting multiple strands of thin copper wire are easier to adapt to frequent deformations than single strands of thick wire.
Tensile strength: Refers to the ability of a lead to withstand tensile force without being pulled apart. During installation and use, the leads may be subjected to certain tensile forces, and sufficient tensile strength can prevent wire breakage faults.
3、 Environmental adaptability performance parameters
Temperature resistance: including the ability to withstand high and low temperatures. When the motor is running, the friction between the carbon brush and the shaft will generate heat. In high-temperature environments, the insulation layer of the lead wire needs to be stable, not melted, and not aged; In low-temperature environments, the lead material should not crack due to embrittlement, ensuring normal operation in different climates or working conditions.
Corrosion resistance: For working environments that are humid, dusty, or contain chemical gases, the surface coating or insulation material of the lead must have corrosion resistance to prevent a decrease in conductivity or structural damage caused by corrosion.
4、 Insulation performance parameters
Mainly manifested in insulation resistance and voltage resistance. The insulation layer should effectively isolate the wire from external metal components to avoid leakage or short circuit. The higher the insulation resistance, the smaller the leakage current; The ability to withstand voltage ensures that the insulation layer is not broken down at a certain voltage, ensuring the safety of equipment and personnel.
These performance parameters are interrelated and need to be comprehensively considered based on the application scenarios of carbon brushes, such as industrial motors, new energy vehicle motors, wind turbines, etc., in order to achieve efficient matching of leads, carbon brushes, and the entire motor system.
