How to solve the problem of Flying Shear Motor brush and commutator failure?

1. Solution to brush wear too fast
Adjust the brush pressure: Use a spring scale to measure the brush pressure and make sure it is in the appropriate range. For Flying Shear Motor, the brush pressure is generally between 15-25kPa. If the pressure is too high, the spring device of the brush should be properly loosened; if the pressure is too low, the spring can be carefully adjusted to increase the pressure so that the brush and commutator are in good contact, while avoiding excessive pressure causing excessive wear of the brush.
Replace the brush: When the brush is worn to 1/3-1/2 of the original length, the brush should be replaced in time. Choose a brush of the same model as the original brush to ensure that the material, size and performance of the brush meet the requirements of Flying Shear Motor. Before installing the new brush, check whether its surface is flat. If there are defects such as burrs, it needs to be gently polished with fine sandpaper.
Dealing with commutator surface problems: If the commutator surface is uneven, has burrs or oxide layers, it will accelerate brush wear. When the motor is stopped, use fine sandpaper (usually 800-1200 mesh) to gently polish the commutator surface to make it smooth. For thick oxide layers, use a special commutator cleaner to clean it and then polish it. At the same time, check whether the mica sheet of the commutator is protruding. If the mica sheet is higher than the commutator surface, it should be engraved so that the mica sheet is 1-1.5mm lower than the commutator surface.
2. Solution to excessive brush sparks
Adjust the brush position: Determine the neutral line position of the brush. The induction method or the forward and reverse generator method can be used for adjustment. The induction method is to apply a low-voltage AC power supply to the main pole winding when the motor is stationary, and then use a millivoltmeter to measure the induced electromotive force at both ends of the brush. When the induced electromotive force is zero, the position of the brush is the neutral line position. After adjusting the brush to the neutral line position, the current transition of the brush during the commutation process can be smoother and the spark generation can be reduced.
Improve the surface condition of the commutator: As mentioned above, the commutator surface is polished, cleaned, and mica engraved to ensure good contact between the brush and the commutator. At the same time, check the roundness and cylindricity of the commutator to ensure that it meets the requirements. If the roundness or cylindricity error is large, the commutator may need to be turned to restore its surface shape to normal.
Check the armature winding: Use an insulation resistance meter or a multimeter to check whether the armature winding is short-circuited or open-circuited. If the winding is found to be short-circuited, for local short-circuit points, the method of strengthening insulation can be used to repair; for situations where the short-circuit range is large, the armature winding may need to be replaced. If the winding is open-circuited, find the break point. If it is a welding problem, re-weld it; if the wire inside the winding is broken, the damaged part needs to be repaired or replaced. After repairing or replacing the armature winding, check whether the insulation of the repaired part is good.