Ring/segment Construction
A commutator consists of a set of copper segments, fixed around the part of the circumference of the rotating machine, or the rotor, and a set of spring loaded brushes fixed to the stationary frame of the machine. Two (or more) fixed brushes connect to the external circuit, either a source of current for a motor or a load for a generator.
Each conducting segment on the armature of the commutator is insulated from adjacent segments. Mica was used on early machines and is still used on large machines. Many other insulating materials are used to insulate smaller machines; plastics allow quick manufacture of an insulator, for example. The segments are held onto the shaft using a dovetail shape on the edges or underside of each segment, using insulating wedges around the perimeter of each commutation segment. For small appliance and tool motors the segments are typically crimped permanently in place and cannot be removed; when the motor fails it is simply discarded and replaced. On very large industrial machines (say, from several kilowatts to thousands of kilowatts in rating) it is economical to be able to replace individual damaged segments, and so the end-wedge can be unscrewed and individual segments removed and replaced.
Commutator segments are connected to the coils of the armature, with the number of coils (and commutator segments) depending on the speed and voltage of the machine. Large motors may have hundreds of segments.
Friction between the segments and the brushes eventually causes wear to both surfaces. Carbon brushes, being made of a softer material, wear faster and may be designed to be replaced easily without dismantling the machine. Older copper brushes caused more wear to the commutator, causing deep grooving and notching of the surface over time. The commutator on small motors (say, less than a kilowatt rating) is not designed to be repaired through the life of the device. On large industrial equipment, the commutator may be re-surfaced with abrasives, or the rotor may be removed from the frame, mounted in a large metal lathe, and the commutator resurfaced by cutting it down to a smaller diameter. The largest of equipment can include a lathe turning attachment directly over the commutator.
Read more about this topic: Commutator (electric)
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