Small Motor Technology
Carbon brushes made by Schunk are the “driving forces” in countless fractional horsepower motors of appliances, toys and power tools for handymen and professionals worldwide. Dozens of Schunk components are in everybody’s household, from washers to blenders and to hair dryers.
Schunk Materials delivers the core elements of any electric motor: Carbon brushes, entire brush holder systems and brush yokes for the transmission of the electric power. We also ensure continued operation even after intensive use: Our products are subjected to continuous durability testing in our own laboratories.
Application - Household
Carbon brushes and a brush systems for washing machines, vacuum cleaners and great many more household appliances.
Special Requirements for Material and Design
Carbon brushes and brush holder assemblies used in household appliances demand special requirements of both material and design.
Our product range includes carbon brushes, brush holders and modules for electro-motors in washing machines, vacuum cleaners, household appliances, hair- and hand-dryers.
Today's motors are designed to be smaller and lighter, while simultaneously increasing rotational speeds.
The Business Unit Small Motor Technology reacted to this trend with material development many years ago. In this context special value is placed on the continuous improvement of the commutation behaviour as well as a steady increase of efficiency.
The Schunk Advantage - Possibility to Eliminate Radio Interference Suppression Coils
Generally, Schunk carbon brushes ensure a low level of radio interference. In many cases, motor design engineers can achieve required radio frequency interference levels entirely without suppression coils (chokes). Resulting in cost reduction as well as space savings.
Schunk Special Development: Sandwich Carbon Brush
Schunk is the world market leader for the manufacture of carbon brushes and holders / modules for washing machine motors. In most application cases, Schunk’s special development, the sandwich carbon brush, is employed: a carbon brush consisting of two halves glued together and separated by an insulating middle layer, a design which decisively reduces leakage current.
For perfect commutation, we have also developed a matching brush holder and module for these carbon brushes. They provide optimal commutation for both Alternating Current (AC) and Direct Current (DC) power supply.
Carbon Brushes and Modules for High-Speed Vacuum Cleaners
We have been involved in the development and production of high-speed vacuum turbines for years. In this field, we offer solutions for all voltage ranges between 100 and 240 volts, as well as for all power ranges, including the most modern generation of motors with power output of up to 2,000 watts and more. The efficiency of the turbines can be measurably increased through the use of our special materials.
Application - Power Tools
Carbon brushes, carbon brush holders, carbon brush modules for power tools.
Professional power tools place the highest demands on electric motors.
Schunk carbon brushes and holders / modules have shown excellent performance in this field.
In addition to research and development, it is the right materials choice combined with superior process technology in our mixing plant our modern production technology which ensures the high quality of our products.
Schunk materials and modules for power tools are tailor-made specifically for use under difficult conditions such as:
• High current densities
• Vibration
• Dust formation
• High rotational speeds
• Exposure to weather conditions etc.
In this context, customers should expect a long operating life, high operational reliability and the possibility to refit with new components.
Application - Minimotors and Micromotors
Micro-carbon brushes - small, finished-molded precision parts for small motors and miniature motors
One field of special knowledge which the Business Unit Small Motor Technology commands is the development and production of small and micro-carbon brushes, i.e. finished-molded precision parts for small and miniature motors.
Micro-carbon brushes are used in minimotors with both wall-current and battery-current supply, for example:
• Small motors for electric razors
• Miniature motors for office equipment
• High-quality motors for use in toys
• Mini-motors for medical applications
• Audio and video devices
The aim of precision motors with very small dimensions is to ensure a relatively high output combined simultaneously with smooth and silent operation.
Physical material properties for mini- and micro-motors are primarily defined by means of
• Coefficient of friction
• Specific electrical resistance
• Rockwell hardness
• Bending strength
• Density
• Metal content
• Admissible peripheral speed
• Constant current density
and designed accordingly.
The secret to success in this case is to find the right balance of these properties.
Schunk can help you to do just that with its many years of experience as well as with comprehensive testing.
Service
Application-specific consulting for the design and engineering of motors and equipment, radio interference measurements, durability tests, solution recommendations
We offer you:
• Application-specific consulting for the design and engineering of motors and equipment
• Radio interference measurements
• Durability tests
• Problem analysis with solution recommendations
• Well-equipped laboratories and electronics test labs
Materials Know-How
Schunk cooperates closely with many motor developers all over the world. We test and optimize the latest product developments in our highly-efficient development departments, such as our chemistry and physics laboratories, the radio interference measurement room as well as the application-technology test-benches. The aim of such close cooperation is to create concrete competitive advantages for our customers. These can be achieved by means of developments in the following fields:
• Increased functional reliability
• Longer operating life
• Lower radio interference levels
• Lower noise levels
• Increased efficiency
• More efficient production
Intensive Development Consultation
In the cooperation with Schunk many motor design engineers actively use our chemistry and physics laboratories, our radio interference measurement room as well as the different application-technology test-benches. We would be very pleased to test your developments and advise you concerning the following subjects:
• Materials: physical values and properties
• Brush design
• Brush guidance, brush clearance and brush pressure
• RFI - Radio Frequency Interference suppression
• Impregnations
• Carbon brush running-in
• Carbon brush operating behavior
• Switch-off and signaling devices
• Use of two different brush materials in one motor.
Why Schunk
• Many years of experience
• On site for you as a global player
• A clearly defined commitment to quality
• A firmly established quality management system
• The individual enterprises within our group are certified according to ISO 9001/9002, and in some cases they are even certified according to QS-9000 or TS-16949
• Intensive development consultation
• Product optimization through cooperative teamwork
• We offer both ready-made materials and support with customer-specific systems solutions
• The development and production of special materials and specialized tool manufacture ensure the highest standard of quality and customized implementation.
Carbon Brushes
Carbon Brushes in electro-motors: washing machines, vacuum cleaners, household appliances, hair- and hand-dryers, shavers, toys, electro-tools for professionals and DIY.
Carbon brushes from Schunk are found worldwide in small motors with a performance of up to 2500W.
We are the market leader with our carbon brushes for series and permanent magnet motors.
Our product range includes carbon brushes for electro-motors in washing machines, vacuum cleaners, household appliances, hair- and hand-dryers, shavers, toys as well as in electro-tools for professionals and DIY.
Our products are characterized by their long lifetime at high performance.
Special impregnations help to suppress radio interference.
Consequently, it is not necessary to integrate parts for interference suppression in the motors.
Motor manufacturers benefit from this advantage by a reduction of fabrication costs.
Carbon Brush Holders
Carbon brushes premounted in a ready-to-install brush holder - specific and custom-tailored
The heart of any motor is formed by the carbon brushes, the brush holders and the commutator for the transmission of electric energy.
Very few motor manufacturers install the carbon brushes in the corresponding brush holders themselves.
As a rule, the customer purchases the carbon brushes premounted in a ready-to-install brush holder.
For this reason, Schunk offers not only carbon brushes, but also the brush holders and complete brush cards which go with them.
We do not merely manufacture these subassemblies according to customer specifications, but we design custom-made solutions together with your experts, right from the start.
To achieve this, you have our experienced engineering staff at your disposal.
Brush Holder Systems / Modules
Movable brush cards and complete brush card systems with integrated interference suppressors, heat monitors and switches
For manufacturers of motors, Schunk not only produces carbon brushes and the brush holders that go with them, but also complete brush cards as well as forward/backward movable brush cards with integrated interference suppressors, heat monitors and switches.
We do not merely manufacture these subassemblies according to customer specifications, but we design custom-made solutions together with your experts, right from the start.
To achieve this, you have our experienced engineering staff at your disposal
Micro-Brushes
High precision parts for small motors and very small motors with line powerd or battery powered minimotors
A special field of Schunk Materials is the development and production of micro-brushes. Micro-brushes are small, pressed-to-size high precision parts for small and very small motors. The microbrushes are applied in line or battery powered minimotors, e.g. in small servomotors, printers, fans, toy motors, etc.
In-house research and development, high-quality production as well as specialized tool construction assure customer-oriented realization of new and innovative products.
In the laboratories of Schunk Materials, the micro brushes are carefully examined regarding their lifetime, interference suppression and noise reduction.