Predictive diagnostics of drives

Drive diagnostics is a set of actions and tools enabling the assessment of the technical condition of motors and gearboxes in drive systems. it can be periodic (manual), continuous (real-time monitoring), or predictive (based on data analysis and artificial intelligence). The goal is to detect faults at an early stage before they lead to costly failures, as well as to optimize device operation – including reducing energy losses caused by improper functioning. Drives account for about 70% of electricity consumption in industry. With proper diagnostics, it is possible not only to reduce this consumption but also to plan maintenance activities in advance and thus avoid costly downtime caused by failures.

Periodic diagnostics

This is one of the most commonly used types of diagnostics, based on cyclical manual inspections. Technicians periodically check parameters such as temperature, vibration level, or bearing condition. Although low-cost, this method has significant limitations – it does not detect anomalies appearing between inspections, so it is reactive in nature. Corrective actions are taken only after a problem occurs, which can result in production downtime. This, in turn, generates huge costs, especially in larger plants where each day of production downtime leads to multimillion losses.

Real-time diagnostics

Online monitoring using sensors (e.g., vibration, temperature, voltage, and current) allows continuous tracking of drive conditions. Detection of misalignment, overloads, excessive temperatures, or power supply irregularities is possible without interrupting device operation. This enables the plant to plan preventive maintenance and significantly reduce the number of downtimes. In practice, this also translates into more stable energy consumption and lower risk of operating drives under increased resistance conditions that generate energy losses.

Predictive diagnostics

The most advanced systems use artificial intelligence and big data to not only monitor the current state of drives but also predict when and how a failure may occur. Vibration, electrical, and thermal data collected by sensors are analyzed by learning algorithms. Thanks to this, the plant receives early warnings – it can schedule service in advance, avoid unplanned downtime, and optimize energy consumption.

Various solutions for diagnosing electric drives are available on the market. These are tools designed with industrial plants like ours in mind, enabling the monitoring of machine operation and efficiency with the help of specialized analyzers.

Such devices enable online and predictive diagnostics, providing:

• instantaneous power monitoring – real-time analysis of drive load,
• current and voltage analysis – detection of surges, phase asymmetry, and power supply instability,
• vibration spectrum analysis – early detection of mechanical damage, imbalance, and bearing wear,
• temperature measurement – thermal control of critical components such as windings and bearings.

Such devices enable online and predictive diagnostics, providing:

Modern drive diagnostics deliver tangible results not only in terms of reliability but also energy efficiency:

• energy loss reduction – by eliminating drive operation under excessive resistance, vibrations, or overloads,
• device operation optimization – better matching motor power to load, avoiding oversizing and unnecessary current consumption,
• extension of component lifespan – avoiding overheating and excessive wear leads to lower energy demand and reduced spare parts consumption,
• better maintenance planning – avoiding unnecessary interventions and energy losses resulting from inefficient inspection schedules.

Lack or improper adjustment of the diagnostic system may lead to serious financial and energy consequences:

• unplanned downtimes – sudden motor failure often means not only costly repairs but also hours-long production line stoppages,
• increased energy consumption – previously undetected problems such as misalignment or overloads cause higher energy demand,
• higher maintenance costs – maintenance based on intuition or time instead of data leads to excessive service interventions,
• shortened equipment lifespan – ignoring minor faults accelerates wear and necessitates component replacements,
• safety hazards – in some industries, drive failure can cause the breakdown of the entire technological system and dangerous situations for people and the environment.

Drive diagnostics are an effective way to improve the energy efficiency of industrial plants. Investing in data-driven solutions is a key element of the development and modernization strategies of many production plants. Various solutions, tailored to specific needs, enable a shift from reactive to predictive maintenance, which not only improves safety and extends equipment life but also supports the achievement of energy and environmental goals.