Thanks Roland & Lee,

 

That makes sense, when I get a chance I'll figure out how to make the brush 
rigging even like ADC.  I moved the rear shorter brushes to the front and 
they're still wearing faster cause they seated first and the long one's never 
completely seated (see about 1/2 contact area under them - same length as new). 
 I noticed when I swapped running locations that the comm is bright copper 
under the shorter one's that are carrying most of the current and a light brown 
under the longer one's that are not.  This color moves with the brushes - and 
the front/rear comm is equally smooth.  That's why I think Roland & Lee are 
correct, that symetrical brush rigging will start the seating process evenly 
and keep it so throughout the life.  It's a positive feedback loop, once one 
brush (rear) group starts getting shorter and drawing more current then it hads 
a snowball effect and keeps doing it even later when swapped to the front 
positions (is 1/4" differential).  I think Roland's brush rotatin
 g works because they haven't burned down more than 1/4" differential (or .2 
milli-ohm differential - when I see the snowball effect go).

 

Best regards,

mark 

 

Hello Mark,
 
As I said before, the rear brushes are shunting the front brushes. The rear 
brushes are closer to the armature circuit connections to the communtator 
bars, thus a more resistance path to the front brushes.
 
This is normal in the three motors that I am using in my EV. I run three 
types of motors in my EV. One is a WarP-9, a WarP-11 and a GE-11 which the 
WarP-11 motor frame is the same frame as a GE-11.
 
I have run the GE motor for 10 years where the rear brushes worn down 1/4 of 
the original length of 2 inches. The front brushes only worn down about 1/8 
inch. Every 10 years as per GE maintenance, pull the motor, check spring 
tension, resistance tests and check the communtator surface.

                                          
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