How motor current signature analysis transforms condition monitoring

Electric motors are vital in industrial settings, but they aren’t immune to failure. Studies show that European industries experience an average downtime of 6.3% from motor failures. This results in economic losses of billions of euros each year.

Condition monitoring techniques, such as Motor Current Signature Analyzing (MCSA), are important tools. They help reduce losses by finding motor problems early. This blog looks at how MCSA can improve uptime and reliability. It does this by analyzing electrical and mechanical signals from motors.

How MCSA works

MCSA reforms motor monitoring by using the motor itself as a sensor to detect both mechanical and electrical faults. Unlike traditional vibration analysis, MCSA identifies early signs of problems by measuring electrical signals—enabling detection long before physical damage manifests. Here’s why MCSA stands out:

• Uses your motor as a sensor: MCSA detects mechanical vibrations through electrical signals. This lets you check motor health without extra sensors.
• MCSA works well in difficult environments. It can operate in dust, water, and extreme conditions. It collects data without any issues.
• Cost-effective and non-intrusive: MCSA uses existing motor currents. This means there is no need for costly vibration sensors or disruptive maintenance checks.

Electrical signals vs. vibration analyzing

While traditional vibration sensors have been a go-to method for fault detection, they come with limitations. Electrical signals give early warnings about possible problems, like torque changes, that often happen before mechanical failures. In environments where vibration sensors struggle—like areas with extreme dust or difficult access—MCSA performs efficiently. Its ability to monitor the whole drive train from the control room makes it more useful in tough industrial settings.

Real-world examples of MCSA in action

MCSA’s ability to catch mechanical and electrical issues before failure is not just theory. In practice, it has proven its value in numerous real-world cases.

• Coupling Failure Detection: In a steel production plant, an MCSA system detected a developing coupling failure. By closely watching the stator currents, MCSA noticed small changes in the motor’s speed. These changes showed wear in the coupling. Maintenance teams intervened before a costly breakdown could occur.
• Gearbox Clearance Issues: MCSA found poor gear meshing in a gearbox before it caused serious damage. The system found unusual noise and small changes in the torque. This helped the team fix the clearance problem quickly, with little downtime.

Linking mechanical and electrical issues

What makes MCSA so powerful is its ability to link mechanical problems to electrical signatures. For example, rotor imbalances create clear electrical signals. These signals are easy to find using MCSA, even before vibration detects them.

Mechanical faults like misalignments or bearing damage often manifest as small changes in the motor current. This allows MCSA to catch them early, enabling proactive measures to avoid catastrophic failures. As a result, businesses can plan maintenance without disrupting operations, thus extending equipment life and improving reliability.

Expanding the reach of MCSA

Why voltage matters: going beyond the motor

MCSA doesn’t just monitor motors—it can evaluate the entire drive train. By adding voltage signals to analyze, the system provides deeper insights, particularly into torque fluctuations. This enables real-time detection of abnormalities that go beyond the motor, such as in gearboxes, pumps, or compressors.

With voltage-extended MCSA, you gain a broader picture of your machinery’s health. You are no longer just watching the motor. Now, you can look at how different parts of the drivetrain work together. This helps you find problems before they become serious.

Torque as a diagnostic tool

Torque, the force that causes rotation, is a critical indicator of a machine’s health. When torque signals are different from normal, it usually indicates mechanical problems. These can include gear misalignments, worn-out parts, or loose connections.

For example:

• Gear mesh misalignments happen when gear teeth do not fit together properly. MCSA can find the torque problems caused by this issue. This allows for quick action to fix the problem.
• Worn-out components: Over time, parts of a machine, such as bearings or gears, wear down. MCSA catches these changes by measuring variations in torque patterns.
• Loosening connections: As components wear, connections can loosen, creating inefficiencies in the system. Torque data helps identify this, ensuring you can tighten connections before they cause operational issues.

Real-world success story

Consider the case of screw deformation in a water treatment facility. MCSA detected an increasing trend in rotor bar passing frequencies and identified deformations in the screw, which was causing abnormal vibrations. The system caught the deformation early, and corrective action was taken to prevent further damage.

Another case involved a greasing problem in a large industrial motor. MCSA was able to detect subtle changes in the high-frequency electrical spectrum, which indicated deteriorating lubrication. While the issue was minor at this stage, it allowed the maintenance team to improve the greasing process before serious damage occurred.

Why MCSA is the future of condition monitoring

Proactive, not reactive

MCSA allows businesses to move from reactive to proactive maintenance. Instead of waiting for parts to break, MCSA identifies issues early, giving you the time to take action. This approach leads to:

• Increased uptime: Equipment stays in operation longer, reducing costly downtime.
• Lower maintenance costs: By addressing problems before they escalate, you avoid expensive repairs or replacements.
• Improved reliability: Regular monitoring and early detection help maintain a high level of operational efficiency, improving overall system reliability.

Next steps for your business

To stay competitive, it’s essential to implement a predictive maintenance strategy. Integrating voltage-extended MCSA into your existing condition monitoring system can give you complete control over your machinery’s health. This proactive strategy reduces the guesswork, allowing you to focus on optimizing performance rather than dealing with unexpected breakdowns.

Prevent breakdowns before they happen

MCSA gives you the ability to see into the future. By continuously monitoring both mechanical and electrical data, you can prevent costly failures and maintain your equipment in peak condition. Get ahead of problems before they happen, and enjoy smoother operations and fewer interruptions.

Want to know more?

Interested in learning more about how MCSA can transform your operations? Check out our latest report on condition monitoring techniques or book a call with our experts. They can demonstrate how MCSA can help your facility stay ahead of the curve and prevent unnecessary downtime.