Samotics FAQ overview

• Connectivity kit: power supply, gateway, switch.
• Motor kit: data acquisition device, current and voltage sensors.

SAM4’s hardware (including the sensors) is installed inside the motor control cabinet powering an asset. No sensors are required on or near the asset in the field.

Electrical signature analysis (ESA) is a technique that analyzes current and voltage sine waves to provide insights into the condition, performance, and energy consumption of electric motors and rotating equipment. Read our detailed article about electrical signature analysis here to learn more.

ESA delivers key benefits over other condition monitoring technologies such as:

• Monitoring assets in inaccessible or difficult-to-access environments
• Detecting both electrical and mechanical failures
• Utilizing trend-based parameters to spot developing failures based on an asset’s specific operating behavior
• Providing alerts on specific deteriorating components before they reach critical severity Delivering energy/performance optimization insights

1. For mechanical failures or asset-specific failure modes (e.g., cavitation in a pump) unique vibrations are generated that travel throughout the drivetrain and reach the motor where they affect the air gap between the rotor and the stator. These vibrations cause variations in the motor’s magnetic field that are visible in current and voltage signals. Then, by translating these measurements into a frequency spectrum, we can compare real-time data to a baseline and identify deviations corresponding to specific failure modes.
2. For electrical failures, SAM4 captures the relevant variations in the current and voltage data and can identify electrical unbalances, harmonic distortion, and more.

SAM4 utilizes current clamps and voltage branches to feed into the data acquisition device (DAQ) for initial processing. It shares this data with our connectivity kit so it can be fully analyzed and processed in Samotics’ cloud. By installing sensors inside the MCC, we are monitoring assets remotely.

SAM4 samples at 20 kHz (20,000 hertz / second). Typically sampling rates for other condition monitoring technologies range from 6 kHz to 10 kHz. Sampling at 20+ kHz brings a higher granularity to the underlying data which creates the capability of identifying a broader spectrum of failure modes.

Samotics is ISO27001 and ISO 9001 certified demonstrating our adherence to the highest industry standards regarding data security and quality management. We additionally perform annual penetration tests to ensure that your data is protected.

This is communicated via our dashboard, automated email alerts, and if we are integrated into existing systems – via an API connection. By using ESA, we can correspond to specific failure modes and their progression in severity, and our team of asset reliability specialists can identify and prescribe the needed maintenance to address the developing failures.

By using the current and voltage data, SAM4 can pinpoint which specific assets consume the most energy, and by understanding their associated performance (e.g., pump efficiency in relation to best efficiency point (BEP)) and process-related information we can identify opportunities for energy savings. A great example of this is our Vitens case study.

We use affinity laws, load, and speed data, and the pump’s performance curve to determine real-time efficiency. You can read about this in more detail here.

• SAM4 is designed with data security in mind, adhering to ISO27001 standards.
• Data is encrypted both in transit and at rest. All data we send is encrypted with TLS 1.2. Communication between the SAM4 gateways and the cloud environment uses HTTPS or MQTT. All communication between the devices (installed hardware) is wired.

It depends on your situation. SAM4’s reliability and accuracy are industry-leading for applications where SAM4 is a strong technical fit (e.g., centrifugal pumps); however, in terms of cost-effectiveness this depends on many factors, including:

• How critical is the equipment to the process?
• What other technologies do you use to monitor your assets?
• What is the cost of downtime when these assets unexpectedly fail?

Fortunately, SAM4’s hardware is installed inside the MCC which protects it from otherwise potentially harsh environmental conditions. SAM4’s software is updated regularly, and lastly, we have dedicated product development teams to ensure that we continuously support our clients’ evolving needs.

We perform a Post Installation Health Check (PIHC) to check if the asset is performing as expected by comparing its baseline with industry standards. In SAM4’s readings, we will see increasing energy levels across the various rotational and supply frequencies associated with the monitored asset even within the learning period.

SAM4 detects vibrations by measuring electrical signals at specific frequencies linked to drivetrain components. By analyzing these frequencies and the drivetrain setup, we can pinpoint which components are failing. For example, unusual activity at belt frequencies indicates a belt issue. SAM4 can also identify faults in direct coupling systems and pinpoint anomalies even with multiple frequencies, helping locate the exact source of the problem.

ESA cannot detect:

• Temperature changes
• Moisture and other forms of contamination
• Lubrication conditions
• The condition of the insulation

Complex assets (grinders, crushers, assets with many rotational components), assets with high load variations, and/or assets with very low supply frequencies (e.g., <10 hz) require a more detailed discussion to understand if these pose limitations for ESA. If you have specific questions regarding ESA’s limitations, please feel free to contact us here.

Not yet, but we are working on it.