Predicting motor failure using smart sensor

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Customer

Indian Multinational engaged in design manufacturing and marketing of products related to Power Generation, Transmission, & Distribution. Incidentally, the company is also one of the largest manufacturers of Electric Motors in India.

Challenge

The customer sought a solution for convert their Electrical Motors into “Smart Motors”, and wanted a solution which was cost-effective, and could be quickly scaled up, thus giving them the ability to offer their customer’s “Smart Motors” for their critical applications which would be self-diagnostic..

Solution

The solution provided is with Infinite Uptime's IDE Smart Sensor and the IDAP Platform. IDEs are installed on both drive and non-drive ends of the Electric motors, which provide real-time data on critical parameters of the motor, namely Mechanical Vibrations, Temperature, and Acoustic signals. The IDE is also capable of providing FFTs of the motor which is critical in pinpointing the root cause of an anomaly.

During the test phase, IDEs were installed on multiple motors in the manufacturing plant of the company, for real-time testing and evaluation

One of the motors used was a DC motor of 56 kW, used on a vertical boring machine. During the evaluation, after few weeks, significant vibrations were observed continuously on this DC motor, on the Y-axis.

FFT generated using IDE and IDAP revealed that vibrations were a result of external factors, and not related to the motor itself. On physical inspection of the motor, it was observed that motor mounting plate (of 5 mm thickness) which was supported by welded angles was sheared, and the support had become non-uniform, leading to significant vibrations of the Y-axis.

Action

The welded mounting was replaced with a solid mounting plate of 20 mm thickness thus addressing the reason for generation of abnormal vibrations.

The manufacturer has decided to use the Infinite Uptime IIoT solution to convert their motors into "Smart Motors” thus bringing better visibility on health parameters of the Motors being used in Critical applications.

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