Complete carbon brush monitoring platform with local operation
i-BRUSH® 2.0 is a plug-and-play, battery-free carbon brush monitoring and diagnostics platform for motors and generators. It combines dedicated local operation, advanced visualization and maintenance forecasting in one complete solution.
With integrated sensors, local HMI operation, alarms and trend analysis, i-BRUSH® 2.0 provides real-time visibility into carbon brush condition and performance. The platform can operate independently or integrate with existing systems, delivering a complete monitoring experience with advanced diagnostics and maintenance forecasting.
System Overview
With knowledge of remaining brush life, the future maintenance can easily be planned to secure uptime. Operating data can be displayed in any PC or HMI display.
Basics
- Can be retrofitted to any existing installation.
- Fits most common brush holder/slip ring designs on the market.
- Regardless of brush grade, all type of brushes are available in i-BRUSH® design.
- Default max 160 brushes, other on request.
- Locally stored operating data.
- Export of data to Excel or CSV format
- Easy access and updates of software
Key parameters
i-BRUSH® 2.0 monitors and logs:
- Brush wear
- Temperature in the brush
- Brush current
- Brush current density
- Current distribution between brushes
- Brush vibrations (optional)
- Temperature & humidity in slip ring compartment
When one of the monitored values deviates outside given framework an alarm is initiated.
Benefits & Features
SECURED AND SAFE OPERATION
- Replacement of brushes is carried out easy and safely.
- Less interactions and inspections of complete slip ring unit.
- Less shutdowns due to maintenance work.
REDUCES COST OF MAINTENANCE
- Decreases need for repairs of potential slip ring damages which reduces downtime.
- Quick overview
- The i-BRUSH® system itself has minimal maintenance and low operating costs. Transmitters can be reused for several brush sets, and no battery replacement is required.
INCREASED WORKFORCE EFFICIENCY
- Enables maintenance staff to check brush condition at any time.
- Reduced site visits for inspection and maintenance.
- Time-saving inspections, with longer intervals.
BETTER & SAFER MAINTENANCE
- Constant monitoring via HMI display alt. control rooms lead to more informed decisions.
- Constant data transfer 7/24
EXTENDS MAINTENANCE INTERVALS
Maintenance is performed based on brush conditions rather than scheduled activities.
QUICK AND EASY INSTALLATION
- Installation of the i-BRUSH® system does not require any specialized expertise, and a minimum of electrical installation.
- Easy installation steps by following provided installation manual
- Boxes attaches by fasteners.
Cyber security
The security in the i-BRUSH 2.0 product complies with the Carbex product security program. As guidance for our cybersecurity program we have consulted and adopted design principles from applicable industry standard frameworks, such as NIST SP 800-100 and NIST 800-160.
Schematic overview i-BRUSH® 2.0
(Click on the image to enlarge it)
Standard Configuration i-BRUSH® 2.0
i-BRUSH® Base Unit
- Control unit with integrated intelligence
- Default max 160 brushes, other on request.
- Multicolor LED display for quick status overview
- Pre-installed program with alarm settings etc
- Internal data storage, with locally hosted software
- Option to connect external system
- Export of data to Excel or CSV format. Subscription of reports as an option
- Standard power supply, AC 100-230VAC
- Dimension: 300 x 300 x 155mm
PoE Receiver
- Built-in temperature/humidity sensor
- M12/M12 Cable – Avalible lengths: 1, 3, 10, 20 & 85 meters
i-BRUSH® Sensor*
- Current
- Temperature
- Vibration
- Wear
- The i-BRUSH® sensor fits most common brushes on the market
*Number of brush sensors depending on number of brushes in application
Transmitters*
- Battery-free transmitters
- Low weight
- Wireless brush communication up to 10m between receiver and transmitter units
- Reusable transmitters
- Customer-specific options on request
*Number of transmitters depending on number of brushes in application
Options
HMI Display
- 12″ multi touch display
- M12/M12 Cable – Avalible lengths: 1, 3, 10, 20 & 85 meters
- Access of installation manual via HMI display
- Barcode scanner
- Dimensions: 380 x 300 x 182mm
Transmitter Validation Tool
- i-BRUSH® Transmitter Validation Tool
- Includes:
- Transmitter contacts
- (Plus/Minus)
- DC power supply
Function & Use
- Used to validate BLE transmitter signals during installation or maintenance
- Confirms correct operation and placement of transmitters
- Helps ensure signal strength and functionality before system startup
Antenna for Atex Area
- Atex antenna for PoE reciver
- Available lenght: 5-15-30 meter cable
Function & Use
- Enables wireless BLE communication in ATEX (explosive) environments
- Used in conjunction with the i-BRUSH® PoE Receiver
- Ensures safe and compliant operation in hazardous areas
Communication
- i-BRUSH® Remote tool with tosibox 375
- Tosibox soft key licence 1 per user/PC
Function & Use
- Provides secure remote access to the i-BRUSH 2.0® Base Unit
- Enables off-site monitoring, diagnostics, and support
- Used by Carbex support team or authorized personnel
Network cables
- Industrial-grade Ethernet cables for i-BRUSH installations
- Available in various lengths to suit your setup
- Ensures reliable and stable data communication
- Designed for industrial environments with high durability and interference resistance
- Plug-and-play connectivity for fast and secure installation
Other options
Communication To DCS System
- Modbus TCP/IP communication to external system
Or
- i-BRUSH® 2.0 HTTP-Rest (API)
USER LICENCE
- HMI communication to PC Client 5 users
CARBVIB
- Vibration analyze tool mils PK-to-PK
Want to know more?
Thomas Lindell
BUSINESS DEVELOPMENT