Anchoring wear sensors in electrical brushing
This invention relates to electrical brushes having a wear sensor in the form of an electrical conductor or lead within the brush body. 
     Such wear sensor leads have, of course, to be insulated from the electrically conductive brush bodies, United Kingdom Patent Specification No. 1,158,298 in the name of Cello-Pak A/S is an example of a brush body incorporating an embedded loop of an insulated conductor extending down to the limit of permissible wear of the brush. However, in the high temperature conditions experienced by heavy duty or heavy current brushes, difficulty is experienced in anchoring the necessary high temperature insulators which are based on materials such as polymers of fluoroethylene. These high temperature insulators have a smooth, generally inert surface that cannot be simply bonded in the brush body to anchor the sensor. 
     It is an object of the present invention to overcome the aforesaid difficulty of anchoring sensor leads in a brush body. 
     According to the present invention an electrical brush assembly has a brush wear sensor in the form of a loop of insulated electrical conductor having two arms joined by a looped end, the arms leading from an upper surface of the brush to a depth equivalent to the point at which brush wear is to be sensed. A pair of fine bores lead from the brush upper surface to meet a transverse hole in a side face of the brush at the wear depth, and each arm of the sensor loop lies in a respective one of the fine bores with the looped end disposed in the transverse hole and joining the respective arms in the fine bores. The transverse hole may be filled with an epoxy resin cement or the like. Assembly preferably is by insertion of the free ends of the arms of the loop of insulated electrical conductor into the transverse hole and thence separately into and through respective ones of the fine bores. 
    
    
     The invention is illustrated by way of example in the Drawings, wherein: 
     FIG. 1 is a side elevation of a brush in accordance with the invention, and 
     FIG. 2 is a front elevation of the brush of FIG. 1. 
    
    
     As shown, a brush 1 has a pair of silastomer sleeved flexible current shunts 2 and 3 located by tamped copper powder connections in the top 4 of the brush. 
     Two fine bores 5 and 6 are drilled from the brush top 4, close to the side 7, and angled towards one another to converge at a short hole 8 drilled transversely from the side 7. Hole 8 is drilled at a depth d from the brush top 4 at which it is desired to sense brush wear. 
     A brush wear sensor 9 in the form of a lead or conductor insulated with TEFLON (Trade Mark) is made into a loop of which the two arms 10 and 11 are each fed into one of the bores 5 and 6 via the side hole 8. The sensor arms are twisted together above the brush and the free ends are connected to a terminal 12. This construction has the advantages of ease of assembly as the lead ends are simple to insert through the side hole 8 into the bores 5 and 6. Also the wear depth d can be set accurately, as it is a combination of the siting of hole 8 and the protrusion into the hole of the loop end 13. 
     Finally, the hole 8 is filled with ARALDITE (Trade Mark) to bond the loop end 13 in the hole 8, to seal the hole and to help to retain the loop and the ends thereof formed as the brush wears past the hole 8. 
     The sensor lead 9 is used in known manner to detect wear by current leakage.