Technology
Electrical Signature Analysis
The future of condition monitoring reads the motor's electrical signal — not a sensor bolted to the machine.
ESA captures current and voltage waveforms at the motor control cabinet to detect faults across the full drivetrain: motor, coupling, gearbox, and driven load.
Why electrical signals?
Every drivetrain component affects the motor's electrical signal. Changes in bearings, alignment, cavitation, or load alter the current pattern the motor draws. ESA measures these patterns to detect faults early — typically weeks to months before failure.
No sensors on the asset
Measure at the MCC, not the machine. No scaffolding, no ATEX permits, no access constraints.
Physics-based detection
Motor current patterns reveal drivetrain condition. Not statistical inference — physical causation.
Fleet-wide coverage
Monitor 100+ motors from a single MCC installation. Economics that justify monitoring your entire fleet, not just critical assets.
Validated at scale
20,000+ assets monitored worldwide. AI models trained on 10,000+ real industrial machines.
Faults ESA detects
ESA detects mechanical and process faults across the drivetrain, directly from the motor's electrical signal. Weeks to months before failure.
Bearing Wear
Spalling and friction in rolling element bearings altering motor load patterns.
Misalignment
Angular or parallel misalignment increasing mechanical load and torque oscillations.
Unbalance
Rotor mass imbalance producing periodic load variation in the electrical signal.
Belt Degradation
Slippage and wear altering rotational load patterns in belt-driven systems.
Cavitation
Vapor bubble collapse in pumps causing fluctuating hydraulic load.
Blockage
Flow restrictions increasing pump load and energy consumption.
How ESA compares
Traditional monitoring instruments individual machines. ESA monitors the entire fleet from the electrical system.
| Feature | Traditional Vibration | MCSA | SAM4 ESA |
|---|---|---|---|
| Sensor on asset | Required | Not required | Not required |
| Installation effort | Days per asset | Hours per asset | One MCC installation |
| Asset coverage | Critical assets only | Limited | Entire motor fleet |
| Fault scope | Mechanical faults | Electrical faults | Mechanical + electrical + process |
| Diagnostics | Manual analysis | Manual analysis | AI + engineer validated |
| Typical cost/asset | $10K+ installed | $2-5K installed | $200-500 |
Understand ESA in detail
Explore the fundamentals, the system architecture, and how ESA compares to traditional methods.
Looking for the full SAM4 system pipeline? See how SAM4 works
See how SAM4 monitors assets your sensors cannot reach
In a short call, we review your asset types and show where Electrical Signature Analysis would detect faults across your motor fleet. Trusted by utilities, metals producers, and energy operators monitoring thousands of motors.