White Paper-1 January 2008 Proper Brush Design significantly improves Life and Performance Situation: Helwig Carbon’s Engineering group was recently approached by a motor manufacturer who was experiencing excess commutator wear and fast carbon brush wear with their 20 Volt DC Fractional Horse Power (FHP) Motor using grade 5106 from another source. Analysis: Helwig’s Team analyzed the brush design thoroughly. A stronger and more flexible wire construction was proposed along with a new carbon material. R&D engineers at Helwig developed a new grade specifically suited for the application. Grade K115 with optimum (35% Copper & 65% Graphite) was developed. Life Tests: Motors were tested by the customer and an engineering audit was performed after 100 hrs and 250 hrs

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