Carbon brush monitoring platform for system integration
i-BRUSH® Core is a carbon brush monitoring platform for motors and generators. It´s designed for seamless integration into existing automation and control systems, providing brush condition data directly to SCADA, PLC and DCS environments.
Collect carbon brush and environmental data and make it available through Modbus TCP/IP and REST API. i-BRUSH® Core enables customers to use their existing control system, visualization and alarm infrastructure while adding reliable carbon brush monitoring. The operator can also access the i-BRUSH system via local network and perform deep analyses using the Carbex HMI software.
System Overview
Basics
- 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.
Key parameters
i-BRUSH® Core 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® Core
(Click on the image to enlarge it)
Standard configurations
- Control unit box IP 54 Dim (mm): 300x300x155, 240-110 V supply
- Pre-installed program with alarm settings etc.
- Internal data storage, with locally hosted software
- POE receiver
- Temperature/humidity sensor
- Cable 1-85 m Main box-POE Receiver
- 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
- HMI display for local network
- MODBUS TCP set-up
- Potential free output contacts
- Bearing vibration sensor
Connectivity
Standard 1: Web HMI
- Local WEB HMI through secure VPN
- HMI display (Option)
Standard 2: HTTPS
- Data transfer to customer control system
Option 1: MODBUS
- Option solution with standard MODBUS protocol
Option 2 (Add-on): Potential free contacts
- Output signal for local alarm system
Want to know more?
Fredrik Eskilsson
BUSINESS DEVELOPMENT