Proprietary Brush-Life Sensor for DC Gearmotors and Motors


Bodine Electric Company has developed a new brush-wear monitoring system for its popular line of 42-frame permanent magnet DC (PMDC) gearmotors and motors. OEM versions of the type 42A products are now available with built-in electronic brush-wear sensors. This proprietary sensor system is fully integrated into the motor housing.
The special sensors indicate when either of the brushes is nearing the end of their useful life. This unique sensor system allows OEMs to electronically monitor brush wear to effectively maintain uninterrupted operation of these PMDC gearmotors or motors. In addition, it eliminates the guesswork in brush maintenance and inspection. Gearmotors and motors that are equipped with this new feature can also accommodate a built-in magnetic encoder, and built-in EMI filtering. Bodine Electric is in the process of seeking patent protection for this new technology. PMDC motors and gearmotors that feature this proprietary design are only available from Bodine Electric Company.
Terry Auchstetter, Manager of Custom Solutions and Business Development at Bodine Electric comments: “This is the sort of value-added and innovative design engineering that sets Bodine apart. One of our customers approached us with the challenge of monitoring brush-wear and motor life in a battery- and solar-powered application. We took care of the motor solution with this new technology, and the customer integrated the sensor feedback into his control system.”  This sensor system is also ideal for remote monitoring of PMDC gearmotors or motors, especially when you don't have a person standing next to a machine all day.

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