How SAM4 supports a sustainable industrial future with the ERGO projects

As global electricity use rises, industries are under pressure to reduce energy consumption and carbon emissions. Electric motors account for nearly half of the world’s industrial power consumption, and many of them operate inefficiently, wasting both energy and money. 

SAM4, a predictive maintenance system, offers a solution by detecting faults in motors and optimizing their efficiency. This blog explores how SAM4 helps businesses achieve sustainability goals by reducing energy waste, cutting costs, and extending equipment life. We’ll cover how SAM4 works, its role in the ERGO project, and how it provides valuable insights to help industries become more energy-efficient.

SAM4 and the ERGO project

SAM4 is an advanced condition monitoring system that uses six high-frequency sensors to measure current and voltage in AC induction motors and other rotating assets like pumps and compressors. By analyzing these signals, SAM4 can detect developing faults early and pinpoint the exact type of failure. This not only increases uptime but also improves energy efficiency.

The ERGO project 

SAM4 is also part of the ERGO project, a collaboration between Samotics and several industry leaders, including Nouryon, Vopak, and Utrecht University. The project focuses on developing system-level monitoring features within SAM4 to identify energy inefficiencies in industrial processes. The goal is to help industries reduce their energy consumption by 15-30%. This initiative highlights SAM4’s dual benefit—preventing equipment failures and enabling companies to make their operations more sustainable.

Optimizing motor efficiency

Electric motors come in various sizes and efficiency classes, and how they perform depends on several factors, such as load and speed. SAM4 uses the data it collects to estimate how efficiently a motor is operating, providing insights that can help reduce energy waste.

How SAM4 measures efficiency 

To calculate motor efficiency, you need both the electrical input power and the mechanical output power. SAM4 measures the electrical input but not the mechanical output. Instead, it estimates efficiency based on load and speed, which can be derived from the current and voltage data it collects.

SAM4 analyzes the load by calculating the motor’s active power—the power actually consumed by the system. It then assesses speed by measuring the relationship between voltage and frequency. Together, these factors give SAM4 a clear picture of the motor’s efficiency, allowing it to suggest ways to reduce energy use.

Rightsizing motors for energy savings 

One common issue in industrial motors is that they are often oversized for their applications. And motors that run below their optimal load waste energy. SAM4 can identify these inefficiencies and recommend rightsizing—using a motor whose maximum capacity matches the highest load it needs to handle.

For example, SAM4 collects data over time to determine the motor’s peak load. If the motor is consistently running below its optimal load, SAM4 will suggest replacing it with a smaller, more efficient motor. By rightsizing motors, businesses can save significant amounts of energy, especially in systems like pumps and fans, where loads can fluctuate.

Real results from SAM4

SAM4’s data-driven insights can help companies make informed decisions about their equipment and processes. In a study of 303 industrial motors, SAM4 found that over half of the motors could be right sized for energy savings, with potential reductions of up to 53%.

Case study: reducing energy use 

SAM4 analyzed data from a motor that was consistently running below its optimal load. By rightsizing this motor, the company reduced energy consumption by over 20%. In fact, the savings from rightsizing just this one motor were enough to power 29 homes for a year. This example shows the significant impact that optimizing motor size can have on energy use and carbon emissions.

Further opportunities for process optimization

SAM4 not only identifies energy waste in motors but also highlights inefficiencies in the processes they power. After rightsizing motors, SAM4 revealed that 20% of the motors in the study were still operating below 40% load. This indicates more opportunities for optimization, such as redesigning processes to distribute the load more efficiently across multiple motors. By taking a closer look at how motors and processes interact, companies can make even deeper improvements in energy efficiency.

SAM4 as a tool for sustainability

SAM4 offers a complete solution for predictive maintenance and energy management. It helps companies prevent equipment failures, reduce downtime, and cut energy waste. With its ability to track motor performance and identify inefficiencies, SAM4 is a useful tool for businesses who want to improve their sustainability efforts.

By using SAM4 to monitor motor health and optimize efficiency, companies can reduce their carbon footprint, lower operational costs, and support long-term sustainability.