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Commutator Design. The tang connect style airgap commutator is one of the most commonly used commutator designs in motor production today. Ac commutator motors, like comparable dc motors, have higher starting torque and higher speed than ac induction motors.

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Brushless dc motors also require commutation, but for brushless designs. Early machines used brushes made from strands of copper wire to contact the surface of the commutator. However, these hard metal brushes tended to scratch and groove the smooth commutator segments, eventually requiring resurfacing of the commutator.

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A commutator is an arrangement of insulated copper bars that are connected to coils of an electric motor to provide a reversal of current into the coils of the motor. When a motor is operating normally, the brush current will vaporise some of the copper molecules and deposit them as a copper oxide film on the commutator, this film is usually uniform tan to charcoal brown in colour. The commutator itself is a split ring, typically made of copper, with each segment of the ring attached to each end of the armature coil. So, the armature of pm dc commutator machine is designed by the same rule of winding layout as in general dc shunt motor