Electric motors are the backbone of many industrial production processes. Essential for converting electrical energy into mechanical energy, these motors drive critical machines and equipment that guarantee the continuity of operations in various industrial plants.
In this article, understand the leading causes and impacts of the most common defects in electric motors, get to know SEMEQ’s new sensor, the Elektron MCA 460V, and learn how it can contribute to predictive maintenance in your industry. Read on!
Motor faults: a common problem with significant consequences
Electric induction motors are fundamental to industrial production processes. They convert electrical energy into mechanical energy and drive machines and equipment critical to continuous plant operation.
However, defects in these motors are a recurring problem that can cause major damage. Significant defects in an electric motor interrupt production and lead to expensive repairs, component replacements, and prolonged downtime.
With these challenges in mind, SEMEQ has developed the Elektron MCA 460V, an innovative sensor that stands out on the market.
Meet SEMEQ’s new sensor: Elektron MCA 460V
The Elektron MCA 460V is SEMEQ’s latest innovation. It is designed to transform the monitoring and maintenance of electric motors in industrial environments.
With advanced constant and remote monitoring features, this sensor is a cutting-edge solution that guarantees operational continuity and equipment integrity.
Next, let’s understand how the Elektron MCA 460V can be used in different industrial contexts.
What makes the Elektron MCA 460V unique?
The Elektron MCA 460V stands out for several innovative features that give it a significant advantage in monitoring electric motors. Check the features below:
- Constant and remote monitoring: allows continuous surveillance of electric motors, ensuring that any anomalies are detected immediately, without the need for continuous physical intervention;
- Low energy consumption: designed to operate efficiently, the sensor consumes little energy, making it ideal for installations that require constant monitoring without significantly increasing operating costs;
- Remotely editable parameters: with the ability to adjust monitoring parameters remotely, users can adapt sensor settings as needed without interrupting equipment operation;
- Over-the-Air (OTA) Firmware Updates: OTA functionality allows the sensor’s firmware to be updated remotely, ensuring that it is always equipped with the latest improvements and security fixes;
- “Force Measure” button: this function allows the user to force a measurement manually, providing additional flexibility in monitoring and analyzing the data collected;
- Easy DIN rail mounting: The Elektron MCA 460V’s design makes it easy to install on DIN rails, making integration with existing systems quick and simple.
Where to use the Elektron MCA 460V?
The Elektron MCA 460V is versatile and can be used in various industrial applications. Its monitoring capabilities are precious in environments where the reliability of electric motors is critical.
Below, we list the main contexts in which the sensor can be applied:
- Manufacturing industries: the sensor can constantly monitor electric motors, ensuring that any faults are detected and corrected before they cause significant interruptions to production;
- Processing plants: it can prevent faults that could interrupt operations and cause financial losses;
- HVAC systems: in heating, ventilation, and air-conditioning systems, monitoring electric motors is essential to maintain environmental comfort and energy efficiency;
- Energy sectors: helps ensure that electric motors operate reliably, contributing to the stability of the electricity grid;
- Transportation and logistics industries: it can help maintain the continuous operation of vehicles and handling equipment.
Primary defects detected by the Elektron MCA 460V
Various defects can compromise the operation of these motors, negatively impacting industrial productivity. Among the main defects detected by SEMEQ’s new sensor are:
Cracked bar
Detects cracked rotor bars caused by overheating, fatigue, excessive vibrations, and overloading.
Current and voltage imbalance
Identifies imbalances that affect the motor’s efficiency, causing it to overheat and reducing its useful life.
Detection of VFD faults and rotor eccentricity problems
The Elektron MCA 460V detects defects that can cause VFD trips, such as short circuits between windings and other critical faults. In addition, the sensor monitors rotor eccentricity problems, which can be caused by neutral or ground faults. These advanced detection capabilities help prevent unplanned downtime and maintain electric motors’ operational efficiency.
Bearing failure
Detects bearing faults that can lead to mechanical failure.
High consumption and fines
Detect inefficiencies that result in high consumption and fines due to reactive power and power quality.
Identification of soft foot and misalignment
The Elektron MCA 460V identifies critical mechanical defects, such as soft foot and misalignment, guaranteeing motors’ precision and optimal operation. In addition, the sensor detects problems in the voltage waveform, indicating possible damage to essential components such as IGBTs, MOSFETs, and magnetic brakes. This enables effective preventive maintenance, avoiding catastrophic failures and reducing downtime.
Success story: how the Elektron MCA 460V saved a production line
The online monitoring system developed by SEMEQ played an essential role in preserving a plant’s production line.
When it was installed and transmitted data, the Elektron MCA 460V detected abnormalities in the spectral composition of the electric motor in operation, explicitly indicating the presence of a fault in the rotor bar, known as the Broken Bar Frequency.
The team at SEMEQ’s Advanced Analysis Center (CAA), led by specialist Fernando Martins, intensively monitored the motor, adjusting the frequency at which data was sent to ensure the accuracy of the diagnosis.
Early fault detection allowed the industrial plant to safely plan maintenance interventions, avoiding an unexpected and potentially catastrophic stoppage on the production line. During the scheduled intervention, the maintenance team, supported by SEMEQ, confirmed the fault through offline tests, validating the accuracy of the Elektron MCA 460V monitoring system.
This preventive action saved the company’s production line from a possible collapse and demonstrated the effectiveness of SEMEQ’s predictive monitoring technology in identifying and managing critical faults in electric motors.
Learn how to implement the Elektron MCA 460V in your operation
Implementing the Elektron MCA 460V in your operation is a significant step towards optimizing predictive maintenance and increasing the reliability of your electric motors. Understand how we carry out this process:
Initial consultation
Contact SEMEQ to schedule an initial consultation. Our experts will conduct a detailed study of your industrial plant’s needs at this stage.
Analysis and planning
Based on the initial study, we identify the critical motors that need constant monitoring. We will define the operating parameters that will be monitored by the sensor and determine the quantity and exact location of the sensors required.
Installation
A specialized SEMEQ technician will visit your plant once to install the Elektron MCA 460V sensors on the designated motors. Installation is quick and efficient, minimizing interruptions to your operation.
Remote monitoring
After installation, monitoring is carried out remotely. The data collected by the sensors is transmitted to the My SEMEQ platform, where it can be viewed and analyzed in real time.
Update and maintenance
Use the Over-the-Air (OTA) firmware update feature to update the sensors with the latest improvements and fixes constantly. SEMEQ takes care of all the necessary updates and maintenance, ensuring your sensors remain efficient and reliable.
Revolutionize your predictive maintenance with the new SEMEQ sensor.
Implementing the Elektron MCA 460V in your operation increases maintenance efficiency and extends the useful life of motors, reducing operating costs and improving overall productivity. Adopting this technology is essential to aligning with Industry 4.0 practices, ensuring that your operation is ahead of the curve in terms of innovation and efficiency.
Find out how the Elektron MCA 460V transforms your predictive maintenance.
Contact SEMEQ today and find out how our solutions can increase the efficiency and reliability of your industrial operation.
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