Vulnerable brush faults can be specifically divided into three types: brush sparking, brush chatter, and uneven brush wear. The reasons for these three problems are as follows.

The main causes of sparking of electric brushes are as follows: problems with the adjustment of the additional pole of the carbon brush; The mica of the generator is too prominent; The connection of the commutator lifting plate is disconnected; The installation position of the electric brush is incorrect; Uneven spacing or arrangement between carbon brushes and brush holders; The commutator or collector ring of the generator is deformed; The commutator of the generator is loose; The commutator blades of the generator generate oil stains; Adhesion occurs between the electric brush and the brush holder, making it impossible to separate properly; The carbon brush does not match the specifications of the generator, or the brush has not yet been fully worn in with the generator.

The specific reasons for causing carbon brush chatter are as follows: the generator's commutator or mica is too protruding, causing the brush to vibrate during operation; The brush holder of the carbon brush is too far away from the commutator or collector ring; The commutator or collector ring of the generator deforms due to prolonged operation; The brush holder of the carbon brush becomes loose due to prolonged operation; Because the brush holder is too loose to fully grip the carbon brush; The carbon brush does not match the type of the generator, or the brush has not yet been fully worn in with the generator.

The main reasons for uneven damage to carbon brushes are as follows: prolonged overload operation of the generator; Oil stains are generated on the commutator or collector ring of the generator; Uneven resistance between carbon brushes and brush dryers; The contact surface of the carbon brush is not cleaned, resulting in fine particles; The uneven distribution of current in the generator leads to uneven wear of the brushes during operation. Another reason for uneven damage to the brushes is the inconsistent specifications of the generator brushes during the assembly process, resulting in the mixing of carbon brushes.

In the face of the problems caused by the malfunction of the carbon brush during the operation steps, it should be resolved through three aspects: pre operation, in operation, and regular maintenance.

To reduce the probability of carbon brush damage in generators, strict control should be exercised when selecting brushes for the generator. Firstly, the surface of the carbon brush should be chamfered appropriately, with appropriate specifications, standardized composition, and the cross-sectional area and length of the wire should meet the requirements, without any looseness, detachment, damage, edge loss, corner loss, clamps, or other issues. Secondly, inspect the brushes through instruments. From a technical perspective, electric brushes should comply with national standards. Again, on the same generator, brushes of the same model and manufacturer should be selected for use. Because the performance of brushes produced by different manufacturers varies greatly, and even the performance of carbon brushes produced by the same manufacturer at different times also varies. Therefore, for the same generator, it is advisable to choose brushes of the same specifications and manufacturing plant, preferably produced at the same time, to prevent the imbalance of parallel carbon brush current distribution caused by differences in carbon brush performance, which may affect the normal operation of the generator.

When the carbon brush is damaged, corresponding solutions should be adopted based on the cause of the damage. Firstly, when sparks occur on the electric brush, there are several steps to solve the problem: when there is a problem with the adjustment of the additional pole of the electric brush, it is necessary to use shunt or adjust the air gap of the additional pole, or change the specifications of the electric brush; When the mica of the generator is too prominent, carve mica underneath or use a more abrasive brush; When there is a fracture at the connection of the commutator lifting plate of the generator, the fracture should be immediately re welded to prevent further expansion of the loss; When the installation position of the carbon brush is not accurate, the brush holder should be adjusted to the correct position; When the spacing or arrangement between the electric brush and the brush holder is uneven, it is necessary to immediately correct the spacing and arrangement of the brush holders; When the commutator or collector ring of the generator deviates, the commutator or collector ring should be re ground; When the commutator of the generator becomes loose, it should be re tightened; When oil stains appear on the commutator blades of the generator, the commutator blades and sealed bearings must be cleaned immediately; When adhesion occurs between the carbon brush and the brush holder, which cannot be separated properly, regular testing and updating of the brush holder is necessary. Secondly, when there is a vibration problem with the brushes, there are several ways to relieve it: when the commutator or mica of the generator is too protruding, causing the brushes to vibrate during operation, the commutator should be tightened and mica should be engraved; When it is found that the brush holder of the carbon brush is too far from the commutator or collector ring, it needs to be adjusted. The normal distance between the brush holder and the commutator is two millimeters; When the commutator or collector ring of the generator is found to be deformed due to long-term operation, it needs to be replaced immediately; When the brush holder that generates the electric brush becomes loose, it is necessary to install fastening plates on the brush holder to ensure control over the carbon brush; When the brush holder is no longer able to grip the electric brush, it should be replaced with new equipment immediately.

Finally, when the problem of uneven wear of the brushes occurs, there are several ways to solve it: for the current situation of uneven brush wear caused by long-term overload operation of the generator, the compliance of the generator should be reduced and limited. Operate the generator within a normal and reasonable range; For the uneven wear of carbon brushes caused by the uncleanness of the generator's commutator or collector ring, regular cleaning of the commutator or collector ring should be carried out; For the uneven wear of carbon brushes caused by uneven resistance between brushes and brushes, it is necessary to clean and reinforce the joint between carbon brushes and brushes; For the uneven damage to the carbon brush caused by not cleaning the contact surface of the carbon brush, it is necessary to re run in and clean the surface of the carbon brush; For the uneven distribution of current in the generator, which leads to uneven wear of the brushes during operation, it is necessary to adjust the voltage of the brushes.

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