Electric Motor & Generator Brushes
For over 86 years, Helwig Carbon has been an industry leader in the replacement brush market, as well as a supplier to many of the major OEMs of DC equipment. Our state-of-the art manufacturing facility allows us to quickly produce custom brushes in a day or two. Helwig Carbon brushes are found throughout industry including steel processing, mining, power generation, papermills, railroad, and motor repair.
The carbon brushes are custom designed and manufactured to meet the requirements of your particular motor or generator. Finding the proper brush design for the operating conditions of your motor is the key to maximizing carbon brush and commutator life. Poor brush selection can result in fast brush wear and damage to the commutator.
Red Top Advantage
Helwig Carbon has pioneered innovations like the Red Top Multiflex brush for improved electrical contact, reduced brush vibration and extended spring life. The Red Top was a Helwig patented feature which has over 50 years of proven field success and has now become an industry standard.
Helwig Carbon manufactures a full range of carbon brushes for a variety of industries including steel, mining, paper, plastics, printing, and more. For over 86 years, Helwig Carbon has been an industry leader in the replacement brush market, as well as a supplier to many of the major OEMs. Our state-of-the-art manufacturing facility allows us to quickly produce custom brushes in a day or two. Over 1,000 popular styles of brushes are carried in stock and ready for immediate shipment.
Over 100 different high quality electro-graphite, graphite, metal graphite, and carbon graphite grades of material are available to manufacture a full line of fabricated or pressed-to-size carbon brushes. Each brush is formulated to maximize brush life and optimize performance for any given application.
For more information please refer to our handy carbon brush field guide, and the seating in carbon brushes video below.
Helwig Carbon manufactures a variety of carbon brushes used on aviation and military applications. Our carbon brushes and special grades are designed to handle the stringent requirements and high altitude common with these critical applications.
- Precision fabrication
- Special custom grades to meet demanding applications
- High altitude treatments for superior performance and longer life
- ISO 9001
- Application analysis and design recommendations
Helwig Carbon has been servicing the mining industry for over 60 years. Our carbon brushes are used on Bucyrus Erie, P&H, LeTourneau, Marion, and Page equipment. We manufacture a full range of carbon brushes specially designed to meet the rigors of the mining applications on draglines, shovels, crushers, conveyors, and loaders.
Pressed To Size
Helwig Carbon has full pressed to size (PTS) capabilities for high volume and custom parts. Our unique capabilities in both molding and machining brushes allow us to provide the highest quality parts using the most economical manufacturing methods. With our extensive application analysis you can be assured of maximum performance and life out of your existing product design.
- In-house tooling capabilities
- Molded-in shunts/wires
- On-site motor test facility
- Kanban, stock and release programs
- Full assembly capabilities
- Quick, expert prototyping available
Fork Lift & Lift Truck
Helwig Carbon manufactures a variety of carbon brushes for battery operated vehicles including forklifts and golf carts. We have several excellent grades of material that are made in-house and provide long life and good performance.
Several of the most popular brushes for lift truck motors are stocked and available for same day shipment. Custom made brushes can be produced in just a few days.
In order to produce a high quality, competitively priced product, we press-to-size the carbon bodies and then do final fabrication.
Helwig Carbon has been supplying brushes for elevator applications for over 86 years. We offer a full line of carbon, graphite, and composite grade brushes designed to dramatically reduce dusting, minimize maintenance time, and maximize brush and commutator life.
Over 60 popular elevator brushes are carried in stock, ready for same day delivery. Custom made elevator brushes can be made in a day or two.
For more information please refer to our elevator brush field guide below.
Power Tool Brushes
Helwig Carbon manufactures a full range of carbon brushes for power tools. We are a long-term supplier to Milwaukee Electric Tool and Robert Bosch. Our carbon brushes are specifically designed to provide excellent performance and long life.
Our unique capabilities in both molding and machining brushes allow us to provide the highest quality parts using the most economical manufacturing methods. With our extensive application analysis you can be assured of maximum performance and life from your existing product design.
- In-house tooling capabilities
- Assembly capabilities
- On-site motor test facility with dynamometer
- Research and development on-site
- Custom grade formulations
- Ultrasonic welding
- Lead free soldering
Traction & Transit
Helwig Carbon has a long history of supplying carbon brushes for traction and transit applications we highly recommend the use of our Red Top Pad for improved performance. We have several excellent grades that provide long life and are constructed to meet the vigorous demands of this application.