Continuous monitoring reveals early changes
Throughout operation, i-BRUSH continuously monitored the electrical behavior in the brush–ring interface. The gradual increase in current spikes indicated that the contact conditions between the brushes and the slip ring were evolving, even though no visible symptoms or operational disturbances had yet occurred. The data provided a clear early warning that something in the system required attention.
Acting on early signals
Rather than waiting for the problem to escalate, the team acted on these insights and scheduled a quick inspection, instead of reacting to a failure. The inspection results confirmed the i-BRUSH analysis. Both the brushes and the slip ring were showing clear signs of wear, validating that the increase in current spikes was directly linked to changes in the interface.
From reactive to planned maintenance
Because the issue was identified at an early stage, maintenance, consisting of machining the ring and reseating the brushes, could be planned and carried out during a scheduled shutdown. This enabled a shift from reactive troubleshooting to a more controlled and predictable maintenance approach.
The cost of unplanned downtime in paper mills
In the paper mill industry, where production is continuous and highly sensitive to interruptions, unplanned downtime has a significant financial impact. A full shutdown can cost anywhere from several hundred thousand to millions of dollars per day, depending on the size of the mill and its production output.
Avoiding even a single unexpected stop can therefore represent substantial savings.
