There are many reasons for the occurrence of carbon brush sparks during the use of diesel generator sets. Uneven carbon brush current distribution and excessive current density of individual carbon brushes are one of the main reasons:

In actual operation, if one or two carbon brushes are jammed due to mechanical reasons, insufficient spring pressure and other reasons, and the current distribution of the carbon brushes is relatively uniform, the current will be shared by the other carbon brushes. However, we must discover and adjust in time. I am afraid that the carbon brush current has been unevenly distributed, causing individual carbon brushes to carry a large load current. When a generator was excited this time, it was found that the measured current of individual carbon brushes was about 200A, and the peak value reached 400A. Such a large current caused contact. The surface current density increases. According to Q=I*IRT, the heat generation is proportional to the square of the current. When the accumulated heat cannot be dissipated, the temperature rises sharply, and sparks are generated on the contact surface of the carbon brush and the slip ring. In addition, after the sparks are generated, the working environment of the carbon brushes becomes worse, and the vicious circle makes the carbon brushes more serious. And under such a large current, the carbon brush braid will burn. After the carbon brush is burned, the large current is transferred to other carbon brushes, causing the same situation with other carbon brushes, forming a vicious circle.

The overheating of the carbon brush causes the elasticity of the compression spring to deteriorate, resulting in insufficient pressure of the carbon brush, causing ignition between the carbon brush and the slip ring, and the slip ring hits the melting point, which increases heat generation. The long-term fire condition of the carbon brush will cause the slip ring to pull, ablate and produce pitting. The high temperature of the slip ring will cause poor contact between the carbon brush and the surface of the slip ring. Slight scratches are produced on the surface of the slip ring when it is slight, and the slip ring is worn and ablated when it is severe.

When scratches occur on the surface of the slip ring. It will increase the friction between the carbon brush and the slip ring, aggravate the abnormal wear of the carbon brush and the slip ring, cause the slip ring to generate more heat, and cause the carbon brush to jump; while the compression spring is under alternating stress for a long time Running, causing the compression spring to fracture and collapse due to fatigue. The final result of this incident was the uneven surface of the slip ring, the cracking of the carbon brush, and the breaking of the compression spring.

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