Product Description
Brush Condition Monitoring (BCM) is a patented, automated system that delivers real-time brush health analytics directly to your control room. Designed for use with removable brush holders, the BCM system enables condition-based maintenance by continuously monitoring vital brush parameters: usable length, vibration, and temperature.
Instead of relying on calendar-based maintenance schedules, BCM allows operators to make informed decisions based on real-time data and historical trends—improving safety, minimizing downtime, and extending brush and collector ring life.
Key Features
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Real-time Monitoring & Analytics
Tracks usable brush length (%), vibration (mils pk-to-pk), and temperature (°F/°C) for each brush. -
Wireless & Secure Data Transmission
Transmits sensor data over a secure wireless link and via MODBUS protocol to your DCS, Historian, or InsightCM system. -
Configurable Alerts & Thresholds
System alerts operators when brush length is low, vibration is high, or temperature exceeds safe levels—based on plant-defined thresholds. -
Touchscreen System Controller
Onsite controller displays brush data via intuitive dashboards and allows easy configuration of alerts and monitoring settings. -
Brush Health Sensor (BHS)
Sensors are integrated into the brush spring and powered by long-life batteries. Simple spring replacement instructions make battery replacement easy. -
Data Archiving & Trending
Historical data is logged and viewable by individual brush, enabling predictive maintenance and informed operational planning. -
Optional Auxiliary Display
Additional local display options available for convenient access to brush health on both sides of your equipment.
Key Benefits
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Reduce Unplanned Outages
Detects early signs of brush wear or failure, preventing catastrophic events like ring fires or flashovers. -
Extend Equipment Life
By managing brush wear proactively, BCM reduces damage to expensive collector rings and associated components. -
Lower Maintenance Costs
Shifts maintenance from scheduled to need-based, cutting down unnecessary inspections and replacements. -
Improve Plant Efficiency
Access to real-time data allows better planning, quicker response, and optimized use of maintenance staff. -
Minimize Physical Inspections
Brush data is available remotely, reducing the need for manual, risky brush checks during operation.
System Components
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Brush Health Sensor (BHS)
Installed inside the spring of EASYchange brush holders, monitors length, vibration, and temperature. -
System Controller
Central touchscreen unit displaying all sensor data, issuing alerts, and archiving history. -
Wireless Network & MODBUS Integration
Sends data securely to DCS, InsightCM, or Historian systems for plant-wide visibility. -
Auxiliary Display (Optional)
Extra display panel for easier local monitoring.
Installation Overview
BCM integrates seamlessly with existing EASYchange brush holders (over 40,000 installed worldwide).
Our team provides onsite installation support, customized to your plant layout.
Installation is typically fast, and sensor integration requires no complex rewiring.
Battery replacement involves simply swapping the brush spring — no need to disassemble the entire sensor.