Failures in electric motors due to brush wear

Electric motors are essential in industry and at home. One of their most important components is the brushes, which are responsible for transmitting current. Understanding the types of brushes and their applications helps improve efficiency and extend the motor's lifespan.

Why do brushes wear out in electric motors?

Carbon brushes perform an essential function: transmitting current to the rotor. Over time, constant friction with the commutator causes them to wear naturally. However, there are factors that accelerate this process:

• electrical overloads.
• Excessive vibrations.
• Dirt or dust inside the engine.
• Misalignment of the manifold.

When working conditions are inadequate, wear occurs earlier than expected, affecting engine efficiency.

Symptoms of brush wear

Detecting the problem early can prevent a major breakdown. Some clear signs of worn wiper blades include:

• Visible sparks on the collector.
• Loss of power or irregular speed.
• Abnormal noises during operation.
• Burning smell or presence of soot.
• Excessive engine heating.

These signs indicate an electrical or mechanical failure that must be addressed immediately.

Consequences of ignoring brush wear

Continued use of an electric motor with worn brushes can cause irreversible damage. The commutator deteriorates, the windings overheat, and energy consumption increases.

Furthermore, the risk of internal short circuits or unexpected shutdowns is much greater, resulting in lost productivity and higher maintenance costs.

How to solve the problem of brush wear

The best strategy is to combine periodic inspections and preventive replacements. Here are some steps recommended by technicians:

• Visually inspect the condition of the brushes every certain number of working hours.
• Measure their length and replace them if they are below the limit indicated by the manufacturer.
• Cleaning the collector with suitable products to remove carbon residues.
• Check the spring pressure, as incorrect pressure accelerates wear.
• Avoid overloads and ensure optimal ventilation.

These practices ensure stable performance and extend engine life.

Preventive maintenance on electric motors

Prevention is always cheaper than repair. Implementing a regular maintenance plan is key.

It includes tasks such as bearing lubrication, internal cleaning, connection inspection, and thermal control.

A well-maintained electric motor not only lasts longer, but also operates more efficiently and with lower energy consumption.

Conclusion

Brush wear is a common but completely preventable failure. Recognizing the symptoms, applying the appropriate solutions, and performing preventive maintenance ensures that electric motors operate without interruption.

Taking care of every component, no matter how small, is the key to avoiding costly breakdowns and keeping production running.