Predictive drive diagnostics

What is drive diagnostics?

Drive diagnostics is a set of activities and tools that enable 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 breakdowns, and to optimize equipment operation – including by reducing energy losses resulting from improper operation. Drives account for approximately 70% of industrial electricity consumption. Proper diagnostics not only reduce this consumption but also allow for advance planning of maintenance, thus avoiding costly downtime caused by faults.

How can problems be diagnosed in an industrial plant?

• Periodic diagnostics

This is one of the most commonly used diagnostic methods, based on cyclical manual inspections. Technicians periodically check parameters such as temperature, vibration levels, and bearing condition. Although inexpensive, this method has significant limitations – it does not detect anomalies that occur between inspections, making it reactive in nature. Corrective actions are taken only after a problem occurs, which can result in production downtime. This, in turn, generates significant costs, especially in larger plants, where each day of downtime leads to multi-million dollar losses.

• Real-time diagnostics

Online monitoring using sensors (e.g., vibration, temperature, voltage, and current) allows for real-time monitoring of drive health. Detection of misalignment, overloads, excessive temperatures, and power supply irregularities is possible without interrupting equipment operation. This allows the plant to plan preventive maintenance and significantly reduce downtime. In practice, this also translates into more stable energy consumption and a reduced risk of the drive operating under high-resistance conditions, which generate energy losses.

• Predictive diagnostics

The most advanced systems utilize artificial intelligence and big data to not only monitor the current condition of drives but also predict when and how failures may occur. Vibrational, electrical, and thermal data collected by sensors are analyzed and processed by learning algorithms. This provides the plant with advance warning, allowing it to schedule maintenance in advance, avoid unplanned downtime, and optimize energy consumption.

Intelligent systems for energy-intensive industries

Various diagnostic solutions for electric drives are available on the market. These tools are designed specifically for industrial plants, allowing us to monitor the operating status and performance of machines using specialized analyzers.

Such devices enable online and predictive diagnostics, providing:

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

Importantly, advanced systems can not only identify irregularities but also learn from historical data, predicting potential failure points in the future. This allows companies to better manage the equipment lifecycle and adapt maintenance activities to the actual technical condition of the machines.

Energy benefits of drive diagnostics

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

• reduced energy losses – by eliminating drive operation under conditions of excessive resistance, vibration, or overload,
• optimized device operation – better matching of motor power to load, which helps avoid oversizing and unnecessary power consumption,
• extended component life – avoiding overheating and excessive wear leads to lower energy and spare parts requirements,
• improved maintenance planning – avoiding unnecessary interventions and energy losses resulting from inefficient maintenance schedules.

Consequences of lack of proper diagnostics

A missing or inadequate diagnostic system can lead to serious consequences, both financial and energy-related:

• unplanned downtime – a sudden motor failure often means not only a costly repair but also many hours of production line downtime,
• increased energy consumption – previously undetected problems, such as misalignment or overloads, increase energy demand,
• higher maintenance costs – maintenance based on intuition or time, rather than data, leads to excessive service interventions,
• shortened equipment lifespan – ignoring minor faults accelerates wear and tear and the need for component replacement,
• safety risks – in some industries, a drive failure can lead to the failure of the entire technological system and hazardous situations for people and the environment.

,,Although implementing electric drive diagnostic systems involves relatively high initial costs, in justified cases, these solutions are more cost-effective. Eliminating downtime, reducing energy consumption, and reducing repair costs translate into real savings. In practice, investing in modern diagnostics can pay for itself in just 1-2 years, and even faster in energy-intensive plants and sensitive production processes.” says Przemysław Kurylas, Operations Director at DB Energy.

Summary

Drive diagnostics is an effective way to improve the energy efficiency of industrial plants. Investing in data-driven solutions is an important element of the development and modernization strategy for many production plants. Various solutions, tailored to specific needs, enable the transition from reactive to predictive maintenance, which not only increases safety and extends equipment lifespan but also supports the achievement of energy and environmental goals.