Development Project for an Electricity-Generating Cattle Brush Prototype for FinnEasy Oy
FinnEasy Oy, founded in 2016, develops products that promote animal welfare. The company’s CEO, Juha Kultanen, is also the inventor of the company’s flagship innovation, the EasySwing cattle brush. Installed in livestock facilities, these brushes let animals scratch and groom themselves. EasySwing brushes are popular with livestock farmers because they are easy to install, durable, safe, and – most importantly – provide environmental enrichment that supports animal welfare.
Kultanen emphasizes durability and reliability at FinnEasy to ensure the brushes do not impose unnecessary costs on farmers. To function properly, the brush must provide enough resistance for the animal to enjoy using it. In the current design, this resistance comes from gravity: the weight of the steel brush resists movement, so the animal must apply considerable force to make it swing.
While considering this resistance mechanism, Kultanen began wondering whether the motion generated by the animals could be captured, stored, and converted into electricity – creating additional value for customers.
He started developing the concept of an electricity-generating cattle brush. In the early stages, he tested different ideas using, among other things, components from electric bicycles. Once the concept had progressed to the point where a functional demonstration prototype was needed for trade shows, he turned to Optotec.
“Optotec was already familiar to me because they had previously completed a small project for us related to another product. They handled that project professionally, which gave us confidence in their expertise. That made them the natural choice for designing the prototype of our electricity-generating cattle brush,” says Kultanen.
Collecting the Right Data Before Designing the Prototype
The project began with Optotec developing several alternative concepts for the energy storage mechanism. Together with the customer, one concept was selected for further development.
However, at an early stage, it became clear that more detailed information was needed before key components – such as the generator size, battery capacity, and gearbox ratio – could be specified. The team needed to understand how animals actually use the brush: how frequently it is used, how long individual sessions last, how much force is applied, and how fast the brush moves. Rather than proceeding directly to the prototype, the project was redirected to first develop a data collection system.
A standard mechanical cattle brush was modified by installing a compact accelerometer inside the frame at the end of the swinging shaft. Similar to the orientation sensor in a smartphone, the sensor measures the device’s position and changes in motion. An Arduino-based data acquisition system was then developed to read the sensor data and transfer it to Microsoft Excel in real time.
The instrumented brush and data logger were installed in a barn for one day. A surveillance camera was also set up so that the recorded data could be compared with video footage whenever necessary. One unusually high data peak, for example, was traced back to a large bull charging into the brush at speed.
The following day, the collected data was processed into a format suitable for use in the prototype design. At the same time, FinnEasy gained valuable insights into brush usage patterns and utilization rates.
Designing and Demonstrating the Prototype
Using the collected data as a foundation, Optotec’s designer developed the prototype. The result included 3D models and manufacturing drawings for a chain-and-sprocket mechanism that converts the brush’s swinging motion into rotational movement to drive a generator. Protective housings for the electrical components were also designed and produced using 3D printing at Optotec’s office.
Kultanen manufactured and assembled the metal components and chain mechanism based on the drawings, after which the required electrical components were installed.
The project resulted in a fully functional prototype, which FinnEasy presented at the EuroTier trade fair in Hanover in autumn 2022.
“To the best of our knowledge, this is the world’s first electricity-generating cattle brush. It attracted considerable interest, especially at a time when energy prices across Europe were at record highs,” says Kultanen.
Project Outcome and Next Steps
“Working with Optotec was a positive experience. The prototype was completed on schedule and successfully demonstrated that it is possible to capture and store the energy generated through the brush’s normal use,” Kultanen says.
The next step is to refine the prototype into a commercially viable product. According to Kultanen, the highest priorities are ensuring durability, reliability, and minimal maintenance requirements.
“These principles guide the development of every FinnEasy product before it reaches the market. The remaining technical challenges are solvable, but they require substantial further product development,” Kultanen concludes.
We look forward to following the continued development of this innovative concept and hope to remain part of its journey.