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Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
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#1
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Carbon brushes, how do they attach the wire?
I was taking to another poster via irc and I wondered how the copper leads are attached to
carbon brushes for motors. There isn't any way I'm trying to google that one. Can anyone here explain the process? Thanks, Wes |
#2
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Carbon brushes, how do they attach the wire?
"Wes" wrote in message ... I was taking to another poster via irc and I wondered how the copper leads are attached to carbon brushes for motors. There isn't any way I'm trying to google that one. Can anyone here explain the process? A lot of them are in molded Wes. Go ahead and smash a bad one with a hammer sometime. JC |
#3
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Carbon brushes, how do they attach the wire?
Wes wrote:
I was taking to another poster via irc and I wondered how the copper leads are attached to carbon brushes for motors. There isn't any way I'm trying to google that one. Can anyone here explain the process? Thanks, Wes All of the ones I've ever seen had a copper "cup" that the carbon brush sat in. The copper thingie has a spring attached to the back side to apply pressure so the brushes stay in contact with the rotor (stator?) in the motor. Richard |
#4
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Carbon brushes, how do they attach the wire?
"John R. Carroll" fired this
volley in : A lot of them are in molded Wes. Go ahead and smash a bad one with a hammer sometime. Well... sintered. The copper wire may be just embedded in the matrix, with some length of it compressed in the finished form, or there may be a ferrule on the end of the wire, or they may dip the end of the braid in some copper/carbon/flux goo, and sinter that at the same time they're doing the body of the brush. In any case, after baking out in a kiln at several tens of tons per square inch on the material, it becomes a near-homogenous solid, with the wire, ferrule, or metal mix embedment firmly incorporated as part of the structure. LLoyd |
#5
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Carbon brushes, how do they attach the wire?
On Fri, 23 Jan 2009 18:43:20 -0500, Wes wrote:
I was taking to another poster via irc and I wondered how the copper leads are attached to carbon brushes for motors. There isn't any way I'm trying to google that one. Can anyone here explain the process? Thanks, Wes Others have said how "they" do it, as in production. It is also easy to plate copper onto carbon, and then solder (or ultrasonically weld) a lead to the copper. I've electroplated carbon rods for a carbon-arc torch in a coke bottle using copper tube for an anode and copper sulfate solution as juice. |
#6
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Carbon brushes, how do they attach the wire?
Others have said how "they" do it, as in production. It is also easy to plate copper onto carbon, and then solder (or ultrasonically weld) a lead to the copper. I've electroplated carbon rods for a carbon-arc torch in a coke bottle using copper tube for an anode and copper sulfate solution as juice. I assume you've done this. Does the copper carbon bond have good mechanical strength? most servo motor brushes have a very small area on the end of the brush. Karl |
#7
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Carbon brushes, how do they attach the wire?
On Jan 23, 6:43*pm, Wes wrote:
I was taking to another poster via irc and I wondered how the copper leads are attached to carbon brushes for motors. *There isn't any way I'm trying to google that one. Can anyone here explain the process? Thanks, Wes Because carbon is conductive you can plate it with copper and then tin the copper or solder to it. Not the only method as little metal boxes and springs also can be used for a mechanical connection, so- it varies. |
#8
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Carbon brushes, how do they attach the wire?
On Sat, 24 Jan 2009 09:14:34 -0500, Karl Townsend
wrote: Others have said how "they" do it, as in production. It is also easy to plate copper onto carbon, and then solder (or ultrasonically weld) a lead to the copper. I've electroplated carbon rods for a carbon-arc torch in a coke bottle using copper tube for an anode and copper sulfate solution as juice. I assume you've done this. Does the copper carbon bond have good mechanical strength? most servo motor brushes have a very small area on the end of the brush. Karl I never tried brushes. I think it would work if one plated a "cap" on, probably not if one just plated on a spot or pad. I think the latter would peel fairly easily. |
#9
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Carbon brushes, how do they attach the wire?
In many cases, contact is only by pressure against the spring inside the brush holder. This seems
to suffice for small motors in the sub-HP range. Bob Swinney "Don Foreman" wrote in message ... On Sat, 24 Jan 2009 09:14:34 -0500, Karl Townsend wrote: Others have said how "they" do it, as in production. It is also easy to plate copper onto carbon, and then solder (or ultrasonically weld) a lead to the copper. I've electroplated carbon rods for a carbon-arc torch in a coke bottle using copper tube for an anode and copper sulfate solution as juice. I assume you've done this. Does the copper carbon bond have good mechanical strength? most servo motor brushes have a very small area on the end of the brush. Karl I never tried brushes. I think it would work if one plated a "cap" on, probably not if one just plated on a spot or pad. I think the latter would peel fairly easily. |
#10
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Carbon brushes, how do they attach the wire?
On Jan 23, 5:43*pm, Wes wrote:
I was taking to another poster via irc and I wondered how the copper leads are attached to carbon brushes for motors. *There isn't any way I'm trying to google that one. Can anyone here explain the process? Thanks, Wes Many patents describe alternative ways of bonding the braid or shunt: http://www.google.com/patents?q=carbon+brush+shunt This one uses powder mixture with hot isostatic pressing (HIP): http://www.google.com/patents?id=3-o...BAJ&dq=5168620 |
#11
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Carbon brushes, how do they attach the wire?
wrote in message ... On Jan 23, 5:43 pm, Wes wrote: I was taking to another poster via irc and I wondered how the copper leads are attached to carbon brushes for motors. There isn't any way I'm trying to google that one. Can anyone here explain the process? Thanks, Wes Many patents describe alternative ways of bonding the braid or shunt: http://www.google.com/patents?q=carbon+brush+shunt This one uses powder mixture with hot isostatic pressing (HIP): http://www.google.com/patents?id=3-o...BAJ&dq=5168620 Yeah, That's what we called "molded". JC |
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