Abstract: A brush assembly for use in a brush holder assembly of an electrical machine is disclosed. The brush assembly includes a carbon brush, an electrically conductive terminal and an electrically conductive lead assembly attached to both the carbon brush and the electrically conductive terminal. In some instances, the electrically conductive lead assembly includes a spliced union located between the electrically conductive terminal and the carbon brush and spaced away from both the electrically conductive terminal and the carbon brush. In some instances, the electrically conductive terminal includes an inner core layer positioned between a first conductive metal layer and a second conductive metal layer.

Abstract: A system for monitoring the wear state of a carbon brush of a brush holder assembly in which the length of the carbon brush is diminished from an initial length as an end of the carbon brush wears away during use. The system includes a wear state monitor, including a sensor, coupled to the carbon brush. The wear state monitor is configured to rotate as the length of the carbon brush diminishes. The sensor is configured to measure an angular displacement of the wear state monitor as the wear state monitor rotates. The measured angular displacement of the wear state monitor correlates to an amount of diminution in the length of the carbon brush.

Abstract: Methods and systems for monitoring a brush holder assembly and/or detecting wear of a brush in a brush holder assembly are disclosed. One method includes sending data from a plurality of remote monitoring locations to a central control unit, where the data may be evaluated in order to monitor states of brushes at a plurality of remote electrical facilities. For example, multiple images of a marker tracking longitudinal movement of the brush may be acquired. A comparison of the images, for example, a comparative imaging technique, such as pixel-by-pixel comparison, may then be performed in order to evaluate a condition of the brush, such as the wear rate, wear state, or life expectancy of the brush.

Abstract: An example brush holder assembly for positioning a conductive carbon brush in contact with a conductive surface of an electrical device is disclosed. In some aspects, the example brush holder assembly includes a brush holder including a backbone extending therefrom and a removable handle. Further, the removeable handle includes a frame releasably engaged with the backbone and a grip secured to the frame. In some aspects, the brush holder assembly includes a removable catch arm removably coupled to an upper beam and a lower beam of the brush holder assembly. Removal of the catch arm allows the upper beam to be disassembled from the lower beam.

Abstract: Example brush holder assemblies of an electric machine are disclosed. An example brush holder assembly of an electric machine includes a carbon brush including an upper surface and a lower surface opposite the upper surface. The brush holder assembly also includes one or more lead wires extending out of the carbon brush at an insertion point on the upper surface and a first cavity extending into the carbon brush from the upper surface at a location spaced away from the insertion point of the one or more lead wires and unobstructed by the one or more lead wires.

Abstract: A system for monitoring the wear state of a carbon brush of a brush holder assembly in which the length of the carbon brush is diminished from an initial length as an end of the carbon brush wears away during use. The system includes a wear state monitor, including a sensor, coupled to the carbon brush. The wear state monitor is configured to rotate as the length of the carbon brush diminishes. The sensor is configured to measure an angular displacement of the wear state monitor as the wear state monitor rotates. The measured angular displacement of the wear state monitor correlates to an amount of diminution in the length of the carbon brush.

Abstract: A brush assembly for use in a brush holder assembly of an electrical machine is disclosed. The brush assembly includes a carbon brush, an electrically conductive terminal and an electrically conductive lead assembly attached to both the carbon brush and the electrically conductive terminal. In some instances, the electrically conductive lead assembly includes a spliced union located between the electrically conductive terminal and the carbon brush and spaced away from both the electrically conductive terminal and the carbon brush. In some instances, the electrically conductive terminal includes an inner core layer positioned between a first conductive metal layer and a second conductive metal layer.

Abstract: Example brush holder assemblies of an electric machine are disclosed. An example brush holder assembly of an electric machine includes a carbon brush including an upper surface and a lower surface opposite the upper surface. The brush holder assembly also includes one or more lead wires extending out of the carbon brush at an insertion point on the upper surface and a first cavity extending into the carbon brush from the upper surface at a location spaced away from the insertion point of the one or more lead wires and unobstructed by the one or more lead wires.

Abstract: Example brush holder assemblies of an electric machine are disclosed. An example brush holder assembly of an electric machine includes a carbon brush including an upper surface and a lower surface opposite the upper surface. The brush holder assembly also includes one or more lead wires extending out of the carbon brush at an insertion point on the upper surface and a first cavity extending into the carbon brush from the upper surface at a location spaced away from the insertion point of the one or more lead wires and unobstructed by the one or more lead wires.

Abstract: Example brush holder assemblies of an electric machine are disclosed. An example brush holder assembly of an electric machine includes a carbon brush including an upper surface and a lower surface opposite the upper surface. The brush holder assembly also includes one or more lead wires extending out of the carbon brush at an insertion point on the upper surface and a first cavity extending into the carbon brush from the upper surface at a location spaced away from the insertion point of the one or more lead wires and unobstructed by the one or more lead wires.

Abstract: Example brush holder assemblies of an electric machine are disclosed. An example brush holder assembly of an electric machine includes a carbon brush including an upper surface and a lower surface opposite the upper surface. The brush holder assembly also includes one or more lead wires extending out of the carbon brush at an insertion point on the upper surface and a first cavity extending into the carbon brush from the upper surface at a location spaced away from the insertion point of the one or more lead wires and unobstructed by the one or more lead wires.

Abstract: Methods and systems for monitoring a brush holder assembly and/or detecting wear of a brush in a brush holder assembly are disclosed. One method includes sending data from a plurality of remote monitoring locations to a central control unit, where the data may be evaluated in order to monitor states of brushes at a plurality of remote electrical facilities. For example, multiple images of a marker tracking longitudinal movement of the brush may be acquired. A comparison of the images, for example, a comparative imaging technique, such as pixel-by-pixel comparison, may then be performed in order to evaluate a condition of the brush, such as the wear rate, wear state, or life expectancy of the brush.

Abstract: Example brush holder assemblies of an electric machine are disclosed. An example brush holder assembly of an electric machine includes a carbon brush including an upper surface and a lower surface opposite the upper surface. The brush holder assembly also includes one or more lead wires extending out of the carbon brush at an insertion point on the upper surface and a first cavity extending into the carbon brush from the upper surface at a location spaced away from the insertion point of the one or more lead wires and unobstructed by the one or more lead wires.

Abstract: A brush assembly for use in a brush holder assembly of an electrical machine is disclosed. The brush assembly includes a carbon brush, an electrically conductive terminal and an electrically conductive lead assembly attached to both the carbon brush and the electrically conductive terminal. In some instances, the electrically conductive lead assembly includes a spliced union located between the electrically conductive terminal and the carbon brush and spaced away from both the electrically conductive terminal and the carbon brush. In some instances, the electrically conductive terminal includes an inner core layer positioned between a first conductive metal layer and a second conductive metal layer.

Abstract: An example brush holder assembly for positioning a conductive carbon brush in contact with a conductive surface of an electrical device is disclosed. In some aspects, the example brush holder assembly includes a brush holder including a backbone extending therefrom and a removable handle. Further, the removeable handle includes a frame releasably engaged with the backbone and a grip secured to the frame. In some aspects, the brush holder assembly includes a removable catch arm removably coupled to an upper beam and a lower beam of the brush holder assembly. Removal of the catch arm allows the upper beam to be disassembled from the lower beam.

Abstract: Methods and systems for monitoring a brush holder assembly and/or detecting wear of a brush in a brush holder assembly are disclosed. One method includes sending data from a plurality of remote monitoring locations to a central control unit, where the data may be evaluated in order to monitor states of brushes at a plurality of remote electrical facilities. For example, multiple images of a marker tracking longitudinal movement of the brush may be acquired. A comparison of the images, for example, a comparative imaging technique, such as pixel-by-pixel comparison, may then be performed in order to evaluate a condition of the brush, such as the wear rate, wear state, or life expectancy of the brush.

Abstract: A system for monitoring the wear state of a carbon brush of a brush holder assembly in which the length of the carbon brush is diminished from an initial length as an end of the carbon brush wears away during use. The system includes a wear state monitor, including a sensor, coupled to the carbon brush. The wear state monitor is configured to rotate as the length of the carbon brush diminishes. The sensor is configured to measure an angular displacement of the wear state monitor as the wear state monitor rotates. The measured angular displacement of the wear state monitor correlates to an amount of diminution in the length of the carbon brush.

Abstract: A system for monitoring the wear state of a carbon brush of a brush holder assembly in which the length of the carbon brush is diminished from an initial length as an end of the carbon brush wears away during use. The system includes a wear state monitor, including a sensor, coupled to the carbon brush. The wear state monitor is configured to rotate as the length of the carbon brush diminishes. The sensor is configured to measure an angular displacement of the wear state monitor as the wear state monitor rotates. The measured angular displacement of the wear state monitor correlates to an amount of diminution in the length of the carbon brush.

Abstract: A brush holder assembly for use in an electrical generator having a moving conductive surface may include a brush holder, such as a brush box, that is configured to be removably mounted to a mounting element on the electrical generator. A carbon brush may be slidingly disposed with the brush holder and may be biased into sliding contact with the moving conductive surface. The brush holder assembly includes a handle that is moveable between an unlocked position in which the brush holder is removable from the mounting element and a locked position in which the brush holder is secured relative to the mounting element. A circuit board is disposed within the handle and includes a sensor that provides an indication of an occurrence of an anomalous and/or threshold condition of the carbon brush.

Abstract: A monitoring apparatus configured for monitoring a carbon brush of a brush holder assembly of an electrical machine. The monitoring apparatus may include a flexible sensor and a signal processing circuit for processing a signal received from the flexible sensor. The flexible sensor may have an electrical resistance that varies based on a radius of curvature of the flexible sensor, wherein the radius of curvature of the flexible sensor may be associated with a deflection of a spring providing a force to engage the carbon brush with a rotating component of the electrical machine. The signal processing circuit may be coupled to the sensor and may be configured to determine a measure of a wear state of the carbon brush using information about the variable resistance of the flexible sensor.