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Production of Carbon Brush

Carbon brush is a block of carbon in an engine or generator that conveys current between the moving and the stationary parts. Carbon brushes are used in automobile motor starters, generators, distributors, etc.  It is a product which is replaced frequently.  It is composed of carbon or graphite with or without metal.

The major operations involved in the production of carbon brush include:

-                      Shearing
-                      Finishing
-                      Assembling
-                      Testing

The carbon block imported from abroad is cut into the required sizes.  Circular saw is used for this purpose.  The finishing work is carried out by sanding and finishing machine.  The copper flexible wire, the copper and brush sheets are all prepared to the required specifications so as to fit to the grade and appropriate characteristics of the carbon brush.

The requirement of carbon brushes are good conducting, high contact resistance (on commutators and slip rings), low coefficient of friction, and high durability.

The copper flexible wire and copper and brush sheet are materials required to prepare the brush holding unit.  After the carbon brush is manufactured conductivity testing is carried out by means of a bridge tester.

The strength of the carbon brush is also measured by strength testing machine.  Having completed the manufacturing and final tests of the carbon brush, the product is labeled and packed for market.

Main Materials and Equipments
  1. Circular saw 
  2. Bench drill (3/4 inches capacity) 
  3. Sanding and finishing m/c 
  4. Ball press 
  5. Conductivity bridge (for testing)  
  6. Strength testing m/c 
  7. Dies and fixtures
The production process of carbon brush has no adverse impact on environment since the solid wastes that could be regenerated in the production process are recyclable.
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