There are three main parameters involved in the operation of carbon brushes. The first one is the mechanical part, which features a slip ring attached to the shaft. This slip ring is what is called a commutator, and a brush is pushed to it using a spring. To ensure effective brush contact, the commutator’s surface should not be too rough, and neither should it be too smooth. Once there is enough contact between the commutator and the brush, the electrical current is transmitted from one end to the other.
It is worth noting that not the whole brush is involved in the contact process. There are small areas called contact spots that contact the slip ring’s surface. These spots should be evenly distributed to avoid damage and maintain brush balance. Highly conductive brushes seem quite efficient, but this would lead to arching at the contact surfaces. As such, brushes with high resistivity are used in both generators and motors. Another thing that would impact the efficiency of carbon brushes is the surrounding environmental factors such as humidity and corrosive gases.
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