Background
The Challenge
The original spring design provided by the customer had:
8 tightly wound turns
49 mm outer diameter
But during use, the spring proved too stiff. It lacked the flexibility required to maintain proper brush contact force, causing:
Difficult assembly
Inconsistent brush contact
Risk of sparking and overheating in the traction motor
To make matters harder, there were no datasheets or reference test reports available—only failed springs and a force requirement.
The Phynyx Solution
With decades of experience as a traction holder and spring manufacturer, Phynyx studied the failure and re-engineered the geometry:
Reduced the turns from 8 to 5
Increased the outer diameter to 59 mm
Optimized coil spacing for greater flexibility
This allowed the spring to compress smoothly while still maintaining the 3.4–3.8 kgf force range.
Results
The re-engineered traction motor brush holder springs were tested and approved for production:
Delivered consistent contact force
Smooth and reliable assembly fit
Cleared for full-scale use in traction motor brush holders
Why Customers Choose Phynyx
This case study illustrates why OEMs and maintenance teams partner with Phynyx Industrial Products for traction motor components. Even when drawings or data are incomplete, we provide reverse engineering, custom spring design, and high-performance brush holder solutions.
If you are searching for a vendor of traction motor brush holders, brush holder springs, or carbon brushes, Phynyx can deliver quality, reliability, and engineering expertise.
About Phynyx Industrial Products
- Explore our range of traction motor parts: www.phynyxind.com/products
- Submit your RFQ: www.phynyxind.com/rfq
