Alternator brushes are carbon blocks or rods made of electrically conductive material, usually consisting of a pair of brushes in contact with a rotor. As the rotor rotates, the contact surfaces of the brushes and rotor create an electric arc, which transfers electrical energy to an external circuit. This process is used to convert mechanical energy into electrical energy and is one of the core working principles of a generator.

Material

Alternator brushes are usually made of a conductive material such as carbon (carbon) or a copper alloy. Carbon is usually a common choice because of its good electrical conductivity, wear resistance, and thermal stability.

Lifespan

The lifespan of alternator brushes depends on various factors, including conditions of use, generator design, and manufacturing quality. Typically, their lifespan can range from tens to hundreds of thousands of miles, depending on how the vehicle is used and maintained.

Failure Issues

Wear and tear: Because alternator brushes come into contact with the spinning generator rotor, they will gradually wear out. When the brushes wear to a certain point, they may not make good contact with the rotor, affecting current transfer and electrical energy production.

Breakage: Alternator brushes can break due to prolonged vibration and stress. This can result in an interruption of the electrical connection, which in turn affects the performance of the generator.

Carbon buildup: During use, brushes may leave a layer of carbon buildup on the generator rotor. This can lead to poor electrical contact and affect the transmission of electrical energy.

Foreign body interference: Sometimes, dust, grease, or other contaminants may enter the generator and cause poor contact between the brushes and the rotor.

Arcing and Sparking: Arcing and sparking may occur when the brushes contact the rotor. Prolonged arcing may cause damage to the brushes and rotor or even cause a fire.

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