What can happen if motor brushes are allowed to wear excessively?

Motor brushes are critical components in a direct current (DC) motor, as they conduct electrical current between stationary wires and the rotating parts of the motor. If the brushes are allowed to wear excessively, they can indeed cause damage to the commutator, which is the part of the motor that the brushes make contact with to facilitate electrical conduction.

When brushes wear down significantly, they may lose their ability to properly make contact with the commutator. This poor contact can lead to arcing and sparking, contributing to further damage. A worn brush can create uneven contact or pressure, leading to increased wear and tear on the commutator's surface, resulting in grooves or pitting. Such damage can impair the motor’s performance, cause overheating, and ultimately lead to motor failure.

This situation highlights the importance of regular maintenance and timely replacement of motor brushes to prevent costly repairs and inefficiencies in motor operation.