# US 11,309,674 B2 · Brush holder assembly monitoring apparatus, assembly, system and method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,309,674 B2 - Document ID: US11309674B2 - Status: Granted - Kind: B2 - Application number: 17/002,975 - Filed: 2020-08-26 - Published: 2020-12-10 - Granted: 2022-04-19 - Earliest claimed: 2007-05-24 - Assignees: Cutsforth, Inc. - Applicants: Cutsforth, Inc. - Inventors: Robert S. Cutsforth - Web page: https://patentgrep.com/patent/US11309674B2 ## CPC - H01R 39/58: Means structurally associated with the current collector for indicating condition thereof, e.g. for indicating brush wear - G05B 19/4065: Monitoring tool breakage, life or condition - G05B 23/0208: {characterized by the configuration of the monitoring system} - G05B 23/0218: {characterised by the fault detection method dealing with either existing or incipient faults} - G06Q 10/06311: {Scheduling, planning or task assignment for a person or group} - G06Q 10/083: Shipping - G06Q 10/1097: {using calendar-based scheduling for task assignment} - G06Q 10/20: Administration of product repair or maintenance - G08B 21/182: {Level alarms, e.g. alarms responsive to variables exceeding a threshold} - H01R 43/002: {Maintenance of line connectors, e.g. cleaning} - H02K 5/14: Means for supporting or protecting brushes or brush holders - H02K 11/20: for measuring, monitoring, testing, protecting or switching (rectifiers H02K11/04; power electronics H02K11/33) - H04L 43/04: Processing captured monitoring data, e.g. for logfile generation - G05B 2219/50185: Monitoring, detect failures, control of efficiency of machine, tool life - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - G06Q: INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR - G08B: SIGNALLING SYSTEMS, e.g. PERSONAL CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - H04L: TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION (arrangements common to telegraphic and telephonic communication H04M) ## Abstract Methods and systems for monitoring a brush holder assembly and/or detecting wear of a brush in a brush holder assembly are disclosed. One method includes sending data from a plurality of remote monitoring locations to a central control unit, where the data may be evaluated in order to monitor states of brushes at a plurality of remote electrical facilities. For example, multiple images of a marker tracking longitudinal movement of the brush may be acquired. A comparison of the images, for example, a comparative imaging technique, such as pixel-by-pixel comparison, may then be performed in order to evaluate a condition of the brush, such as the wear rate, wear state, or life expectancy of the brush. ## Claims ### Claim 1 A system for monitoring a brush holder assembly comprising: a brush holder; a carbon brush slidably disposed within the brush holder, the carbon brush configured to contact a rotating conductive surface of an electrical generator to conduct electrical current therefrom, the brush holder permitting linear movement of the carbon brush toward the rotating conductive surface as the carbon brush wears; a brush wear indicator configured to provide data indicative of linear displacement of the carbon brush relative to the brush holder associated with wear of the carbon brush, the brush wear indicator including a base portion having a lower surface and an upper surface opposite the lower surface, the lower surface of the base portion attached to a top surface of the carbon brush; a spring having a coiled portion engaging the upper surface of the base portion to advance the carbon brush towards the rotating conductive surface; and a processing unit configured to analyze data indicative of linear displacement of the carbon brush relative to the brush holder; wherein the processing unit is configured to determine a wear rate of the carbon brush. ### Claim 2 (depends on 1) The system of claim 1, wherein the processing unit includes a monitor for displaying information related to the wear rate of the carbon brush. ### Claim 3 (depends on 1) The system of claim 1, wherein the processing unit is configured to send an alert of an anomalous or threshold condition of the carbon brush. ### Claim 4 (depends on 1) The system of claim 1, wherein the processing unit is configured to schedule maintenance of the brush holder assembly. ### Claim 5 (depends on 1) The system of claim 1, wherein the processing unit is configured to route personnel to the brush holder assembly. ### Claim 6 (depends on 1) The system of claim 1, wherein the base portion is configured to move with linear movement of the carbon brush. ### Claim 7 (depends on 1) The system of claim 1, wherein the base portion is in interlocking engagement with the carbon brush. ### Claim 8 (depends on 1) The system of claim 1, wherein the base portion includes a male interlocking portion engaging a complementary female interlocking portion of the carbon brush. ### Claim 9 (depends on 8) The system of claim 8, wherein the male interlocking portion is a tab and the female interlocking portion is a channel receiving the tab. ### Claim 10 (depends on 1) The system of claim 1, wherein the upper surface of the base portion includes a recess bordered by raised edges. ### Claim 11 (depends on 10) The system of claim 10, wherein the recess constrains the coiled portion between the raised edges. ### Claim 12 A system for monitoring a brush holder assembly comprising: a brush holder; a carbon brush slidably disposed within the brush holder, the carbon brush configured to contact a rotating conductive surface of an electrical generator to conduct electrical current therefrom, the brush holder permitting linear movement of the carbon brush toward the rotating conductive surface as the carbon brush wears; a brush wear indicator configured to provide data indicative of linear displacement of the carbon brush relative to the brush holder associated with wear of the carbon brush, the brush wear indicator including a base portion having a lower surface and an upper surface opposite the lower surface, the lower surface of the base portion attached to a top surface of the carbon brush; a spring having a coiled portion engaging the upper surface of the base portion to advance the carbon brush towards the rotating conductive surface; and a processing unit configured to analyze data indicative of linear displacement of the carbon brush relative to the brush holder; wherein the processing unit is configured to determine a wear state of the carbon brush. ### Claim 13 (depends on 12) The system of claim 12, wherein the processing unit includes a monitor for displaying information related to the wear state of the carbon brush. ### Claim 14 A system for monitoring a brush holder assembly comprising: a brush holder; a carbon brush slidably disposed within the brush holder, the carbon brush configured to contact a rotating conductive surface of an electrical generator to conduct electrical current therefrom, the brush holder permitting linear movement of the carbon brush toward the rotating conductive surface as the carbon brush wears; a brush wear indicator configured to provide data indicative of linear displacement of the carbon brush relative to the brush holder associated with wear of the carbon brush, the brush wear indicator including a base portion having a lower surface and an upper surface opposite the lower surface, the lower surface of the base portion attached to a top surface of the carbon brush; a spring having a coiled portion engaging the upper surface of the base portion to advance the carbon brush towards the rotating conductive surface; and a processing unit configured to analyze data indicative of linear displacement of the carbon brush relative to the brush holder; wherein the processing unit is configured to determine a life expectancy of the carbon brush. ### Claim 15 (depends on 14) The system of claim 14, wherein the processing unit includes a monitor for displaying information related to the life expectancy of the carbon brush.