Common Issues and Maintenance Methods for Motor Commutators

Commutators encounter various typical issues during prolonged use. Surface oxidation is a common occurrence, particularly in high-temperature, high-humidity environments or when motors remain idle for extended periods. Oxidation layers increase contact resistance, leading to degraded motor performance and overheating. Regular inspection and cleaning of the commutator surface is an effective method to prevent oxidation problems. Using specialized commutator cleaners can remove oxidation layers without damaging the copper segments.

Commutator segment burning is another frequent failure, typically caused by overload operation or improper brush pressure. Localized burning creates surface irregularities that accelerate brush wear and spark generation. Minor burns can be repaired through precision turning, while severe damage requires replacing the entire commutator. Preventing burning hinges on ensuring proper brush-to-commutator contact to avoid excessive local current density.

Brush sparking is a common phenomenon during commutator operation, but excessive sparking accelerates wear on both the commutator and brushes. Sparking arises from multiple causes, including mechanical factors (e.g., commutator eccentricity, brush vibration), electrical factors (e.g., excessive commutation induced electromotive force), and chemical factors (e.g., damage to the commutator surface coating). Spark levels can be effectively controlled by adjusting brush position, selecting appropriate brush materials, and maintaining a clean commutator surface.