A spark-free industrial revolution

In a significant stride for industrial innovation, Iranian engineer Behnam Alizadeh Qeshlaq has unveiled a homegrown collector cable system that operates without the need for carbon brushes. Presented at the Asr-e Omid (Era of Hope) technology event in the Northwestern city of Tabriz, this breakthrough has the potential to transform energy transmission in multiple heavy industries. The system is already showing promising results in test applications across steel, iron smelting, and tractor production facilities.

An end to sparks & slippages

Traditional carbon brushes are vital in many machines for transferring electrical current between stationary and moving parts. However, they come with challenges. According to Alizadeh Qeshlaq, the main issue with carbon brush systems is surface vibration and slippage, which can generate sparks. These sparks not only pose fire hazards but also lead to frequent production halts, particularly in furnaces and automated systems. The new collector system completely eliminates these risks.

Eliminating imported reliance

For years, Iran relied heavily on imports for carbon brush systems, especially those used in electric arc furnaces and rolling mills. These devices must withstand extreme heat, high mechanical stress, and abrasive working environments. Now, with an indigenously developed solution, the country moves closer to self-reliance in one of its key industrial domains. “Our system has had no recorded failures in over two years,” Alizadeh Qeshlaq affirmed confidently.

Silent but strong: the performance promise

Since the project’s launch two years ago, engineers have monitored the system’s real-time performance under full operational stress. It is designed to function continuously without interruptions, unlike traditional systems that required periodic maintenance due to wear and tear. Alizadeh Qeshlaq noted that no reports of malfunctions or operational pauses have been submitted so far, a sign of engineering reliability and robustness.

Applications across sectors

The new cable collector is not limited to a single industry. It can replace outdated systems in steel plants, iron smelting factories, rolling mills, and tractor assembly lines. These are all sectors that demand consistency, resistance to high temperatures, and strong electrical current management. By removing carbon brushes from the equation, the system reduces the need for routine maintenance and improves long-term efficiency.

Environmental & operational dividends

While the primary benefit is operational continuity, the innovation may also offer environmental advantages. Carbon brushes, due to friction, release microparticles and sometimes cause CO₂ emissions through energy inefficiency. The new system, by eliminating friction and sparking, can potentially reduce indirect emissions and improve overall energy conversion ratios, helping industrial firms meet stricter environmental compliance norms.

Supporting Iran’s tech sovereignty

The launch of this collector cable system is also a symbolic move in Iran’s ongoing quest for technological sovereignty. By reducing its dependency on imported industrial hardware, the country aims to build more resilient manufacturing chains. Events like Asr-e Omid highlight this shift, bringing local inventors, engineers, and firms together to showcase solutions born out of domestic expertise and necessity.

Looking ahead

Although details about mass production and export plans remain under wraps, insiders suggest the company is in discussions with several major industrial stakeholders for large-scale deployment. If successful, this carbon-brush-free cable collector could become a staple in Iran’s factories, and potentially attract attention in foreign markets facing similar operational constraints with traditional systems.

Key Takeaways

• Iran’s new industrial cable collector system eliminates the use of carbon brushes, reducing sparks and unplanned factory halts.

• The system has worked without malfunction for over two years and is suitable for high-stress sectors like steel & tractor manufacturing.

• The innovation supports Iran’s goal of reducing reliance on imported industrial components, also offering potential environmental benefits.