Simple cloud-based brush monitoring and visibility
In generators and motors, brush wear is unavoidable — but costly failures don’t have to be. i-BRUSH® Connect turns maintenance from reactive to predictive, delivering smarter operations and measurable savings. One smart brush. Total control.
Traditional manual inspections are time-consuming, disruptive, and potentially hazardous. i-BRUSH® replaces uncertainty with precision. With 24/7 connected monitoring, you always know exactly when service is needed, not too early, not too late. The result? Increased equipment reliability, fewer unplanned shutdowns, extended component lifespan, lower maintenance costs & greater operational control.
i-BRUSH Connect® - carbon brush monitoring system
Overview
- Can be retrofitted to any existing installation
- Fits most common brush holder/slip ring designs on the market with no modifications.
- Regardless of brush grade, all types and makes of brushes are available to be fit i-BRUSH design.
i-BRUSH® monitors and logs
- Brush wear
- Brush temperature
- Brush current ampere
- Brush current frequency
- Temperature & humidity in slipring compartment.
Settings
- Celsius / Fahrenheit
- Metric (mm) / USCS (in)
- Wear activation threshold %
- Wear activation threshold “Time to maintenance” in days
- Device Sample interval. (Minutes)
- Warnings / Alarms
Brush Wear %
Brush Temperature C/F
Current in Amps
Enclosure Temperature C/F
When one of the monitored values deviates outside given framework an alarm is initiated through the chosen communication set-up.
Benefits & Features
Safe, Secure & Informed Operation
Give your maintenance team the control they need to operate safely and proactively. With continuous real-time monitoring, the i-BRUSH® system provides constant condition data, enabling better and faster decisions. Built-in warning alarms alert operators well before a critical event occurs, giving valuable time to act and prevent costly failures. The system also delivers actionable data for deeper analysis and performance optimization. The result is increased safety, improved control, and fewer surprises.
Lower Maintenance Costs — Higher Operational Efficiency
- i-BRUSH® is designed to reduce total maintenance costs while protecting critical equipment
- Reduces emergency repairs and unplanned interventions
- Enables remote troubleshooting with real-time data access
- The intelligent “Time-to-Maintenance” function makes service planning simple and efficient. Brushes can run longer, safely and in a controlled way — maximizing their full lifecycle value.
- The system is designed for cost efficiency, with minimal maintenance requirements and low operating costs.
Designed for straightforward installation
- The i-BRUSH® system is engineered for simple installation in both new and existing equipment
- For retrofit applications, installation is limited to: Connection of the main box to a 110/230 V power supply
- Mounting of the transmitter inside the brush chamber using quick fasteners in five different configurations.
- No specialized expertise or complex electrical modifications are required. The system is designed to minimize installation time and operational disruption while ensuring reliable and stable operation.
Schematic overview i-BRUSH® Connect
(Click on the image to enlarge it)
Standard configurations
- Control unit box IP 54 Dim (mm): 200x200x120, 240-110 V supply
- Pre-installed program with alarm settings etc.
- Built in receiver
- Temperature/humidity sensor
- Prefered amout of sensor brush fitment for the application
- Prefered amout of transmitters suitable for the application. Available in one- and two-channel versions and five different mounting options to choose from
Options & accessories
- Extra environmental sensors
- External recieiver antenna up to 30m (98ft)
- Monthly report subscription with individual data per unit, as well as a consolidated report highlighting slip ring systems with defects
- Bearing vibration sensor
- Box-free version for installation in an existing control cabinet
Connectivity
Option 1: 4G
- Modem with SIM-card and built-in firewall
- Data transfer via HTTPS to the i-BRUSH cloud homepage or to the customer’s cloud
Option 2: Using existing customer network connection
- Security by existing firewall
- Data transfer via HTTPS to the i-BRUSH cloud homepage or to the customer’s cloud
Want to know more?
Fredrik Eskilsson
BUSINESS DEVELOPMENT