Carbon Brushes

Efficient power transmission thanks to carbon-based materials

High-quality carbon brushes keep industrial systems and household appliances running smoothly. As sliding contacts, they are essential for the safe transmission of electrical current between stationary and moving parts – and are used in a wide range of applications, from power tools and domestic tumble dryers to steel rolling mills, wind turbine generators, hydropower stations, and slip ring systems. Discover Schunk Group's individually configurable carbon brushes! These small but powerful components play a crucial role in ensuring high reliability in electric machines, slip ring systems, and linear current transmission systems.

Carbon brushes: small components, big responsibilities

Carbon brushes are as diverse as the applications they serve. The right design depends on the specific application, the available installation space, and both the electrical and mechanical design. On the electrical side, current and power are key. On the mechanical side, the forces at work matter, such as the contact force on the commutator, vibrations and oscillations, and commutator out-of-roundness. Below, we present the key aspects that influence the design of carbon brushes.

The material

Material selection is based on decades of experience working with OEMs and system operators, combined with application-specific data. Many additional factors also influence the choice:

Electrical properties
Operating conditions
Peripheral/sliding speed
Environmental conditions such as dust, humidity, surrounding media, and temperature
Counterpart material
Level of vibration
EMI susceptibility

The contact surface – in contact with the counterpart

An optimized contact surface geometry and, where necessary, various impregnations ensure that the carbon brush adapts quickly to its counterpart. This prevents pre-damage, premature wear, and extended run-in cycles of the sliding contacts.

Electric motors – tailored solutions for all requirements

Carbon brushes in electric motors must meet various specific requirements depending on the field of use – from high speeds to changing loads and extreme environments. Key is the precise matching of material, geometry, and impregnation to the conditions to ensure efficiency, service life, and operational safety in industrial, household, or niche markets.

Carbon brushes for electric motors

Slip ring applications – reliability under the harshest conditions

Various slip ring applications require specially adapted carbon brush solutions – especially for the safe transmission of signals and power under diverse conditions. Whether in high-tech medical systems, large-scale industrial equipment, or marine environments, the right material combination and thoughtful design are essential for uninterrupted, long-term performance.

Carbon brushes slip ring applications

Generators – carbon brush solutions for modern power generation

Generators place high demands on carbon brushes – including varying sliding speeds, changing loads, and extreme environmental conditions.

Carbon brushes for generators

Special applications – carbon brushes for unique fields of use

In addition to classic use cases, carbon brushes also perform reliably in a variety of specialized applications. We draw on decades of experience to develop appropriate solutions. This ensures continuous, reliable operation even under special technical conditions.

Carbon brushes for special applications

Railway applications – carbon brushes & brush holders for railways

High-quality carbon brushes and brush holders for the railway sector – designed for maximum reliability and performance. Whether for maintenance, replacement, or retrofitting, Schunk components in original equipment quality keep your pantograph and third-rail systems running at their best.

Carbon brushes for railways

Automotive Industry – carbon Brushes for the automotive applications

World market leader in automotive carbon brushes – several hundred million units installed annually. Custom-engineered material grades for traction motors, fuel pumps, comfort and safety systems.

Carbon brushes for automotive

Carbon brush contacting methods

In the simplest case, contact is made via the spring in the brush holder. However, this method can lead to weaker contact force under current load as springs may lose tension. The most common method is embedded stranded wires (litz wires). These can carry much higher currents and also provide high mechanical stability. Depending on the application, multiple litz wires can be used. We offer a wide variety of connectors and terminals depending on the application. Depending on the material combination, connections can be soldered, crimped, or welded.

Optional add-on functions for carbon brushes

Wear indicator: When brush wear reaches the defined limit, a signal is generated via a separate wire, notifying the operator that brush replacement is due soon.
Cut-off device: At a defined wear limit, this device lifts the brush from the commutator, interrupting the current. This protects the commutator from damage due to further motor operation after the brush is worn down.
Damping device: A damping element at the brush head reduces vibrations between the brush and the commutator. This can significantly reduce arcing and wear, as well as damage to the counter surface.

Proven Millions of Times Over

Solutions for DC drives, signal transmission, slip ring systems, household devices, power tools, and wind turbines

Our experts’ many years of experience and our globally positioned organization make us a competent partner for numerous manufacturers of electric motors used in power tools, home appliances, and for the rail, automotive, and wind energy sectors. Whether it's carbon brushes, brush holders, brush monitoring systems, contacts, shaft grounding, or carbon-fiber components for shaft grounding – our solutions are characterized by innovation and in-depth development consulting. We offer a wide range of materials and application-specific designs. An in-house, professional testing laboratory further ensures consistent high manufacturing quality. Take our micro carbon brushes, for example: Even these tiny components – with a volume of just a few cubic millimeters – are packed with high-performance capabilities.

Order Guide: Carbon Brushes

Industrial engines and public transport technologies

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Brochure: Current Transmission

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Physical Data: Carbon Brushes

for industrial and railway applications

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Brochure: Driven by Imagination

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