Know a brush is failing weeks before it does.
Cortelagence retrofits wireless sensors onto your existing carbon brush gear and turns every motor into a live feed — wear, temperature, current and humidity, streamed to one dashboard across every site you run.
Brush Wear
62%
Enclosure Temp
48.2°C
Current Draw
112A
Time to Maint.
18days
Predicted threshold breach in 18 days — maintenance window suggested for next scheduled outage.
94%
of failures showed a detectable wear signature 2+ weeks out
<3 hrs
average retrofit time per motor, no rewind or downtime
100%
wireless, battery-free sensors — nothing to replace
24/7
fleet-wide monitoring across every site, one dashboard
Brush failure is a scheduling problem wearing an engineering disguise.
Most fleets still run on calendar-based inspection — someone walks the floor, eyeballs the brushes, writes a number down. Between visits, a motor can go from “fine” to “unplanned outage” with nobody watching.
The cost isn't the brush. It's the production line behind it, the emergency callout, and the commutator damage that a worn brush causes on its way out.
Every brush becomes a sensor. Every motor, a data point.
We clamp battery-free wireless sensors onto your existing brush holders — no rewind, no downtime — and stream wear, thermal, current and humidity data continuously.
Our models turn that stream into a projected time-to-maintenance date, so your team plans the fix instead of reacting to the failure.
Everything a reliability team needs. Nothing an IT team fears.
Brush wear, to the %
Continuous contact-length measurement per brush — not a monthly visual check.
Thermal monitoring
Brush and enclosure temperature, flagged the moment a hot spot starts trending.
Per-position current
Amperage and frequency at every brush position — catch imbalance before it eats brushes.
Environmental sensing
Humidity inside the slip ring compartment, where moisture ingress does the most damage.
Thermal & current anomaly ML
Beyond thresholds — models trained on real failure signatures flag what a static limit misses.
Time-to-maintenance
A projected service date per motor, not just a red light after the fact.
Fleet-wide dashboard
Every motor, every site, one screen — ranked by urgency, not buried in per-unit reports.
CMMS & alert integrations
Maintenance alerts and work orders routed straight into SAP PM, Maximo, Slack, or Teams — plug into the tools your team already runs.
From clamp to alert in five steps.
Reliability teams don't like surprises. Neither do we.
“We used to find out about brush failure when the alarm panel did. Now we get eighteen days' notice and a work order writes itself.”
“Retrofit was faster than the toolbox talk beforehand. Three motors, one afternoon, no rewind.”
“The fleet view is what sold our reliability team — forty-plus slip ring motors across two sites, ranked by urgency on one screen.”
See your first wear trend before the week is out.
Book a 20-minute call with our engineering team. Bring your motor list — we'll tell you exactly what a retrofit looks like on your fleet.