The Main Structure and Components of a Commutator in a Brushed Motor

The Primary Structure and Components of a Brushed Motor Commutator

A complete motor commutator comprises multiple precision components working in concert. Commutator segments serve as the core elements, typically crafted from high-purity electrolytic copper due to its superior conductivity and wear resistance. These copper segments are machined into specific shapes and then assembled with precision to form a cylindrical structure. Each commutator segment is separated by mica or other high-performance insulating materials, ensuring electrical isolation while withstanding mechanical stresses generated by high-speed rotation.

The commutator's support structure is equally critical. A base, usually made of high-strength phenolic resin or specialized engineering plastics, provides mechanical support and insulation for the entire commutator. This base must withstand high temperatures, centrifugal forces from high-speed rotation, and continuous friction from the brushes. In modern high-performance motors, the commutator base may utilize metal materials, but its surface undergoes specialized insulation treatment to meet electrical performance requirements.

The brushes are the critical components in direct contact with the commutator, typically made of graphite or graphite-metal composite materials. Spring mechanisms maintain appropriate contact pressure between the brushes and the rotating commutator surface, ensuring reliable current conduction. The selection of brush materials and pressure regulation significantly impact the commutator's operational performance and service life, necessitating careful design and selection based on specific application conditions.