From Threshold Settings to Analysis, Diagnosis, and Root Cause Identification—Let AI Handle Your Motor Maintenance!

Do you need a solution to prevent downtime and avoid various losses,
but without the hassle of complex processes? Analog Devices' predictive maintenance solution, the ADI OtoSense Smart Motor Sensor (SMS), is the answer.
As the industry's first AI solution, SMS uses AI to perform everything from threshold setting to analysis/diagnosis, cause identification, and even recommending corrective measures.
Let AI handle it, and you’ll not only prevent unplanned downtime due to faults or false signals but also decrease the number of routine maintenance tasks. Take the next step with SMS to create a smarter factory.

In factories like these! Fields where SMS excels:

• 

  Food/Beverage

• 

  Automotive

• 

  Iron manufacture

• 

  Paper/Pulp

From Installation to Data Acquisition in Just 15 Minutes

Installing SMS is simple, just clamp it onto the motor's fins.
The magnetic field sensor can detect conditions without the need for a physical electrical connection. Data acquisition begins in just 15 minutes after installation.

Reduces False Alarms by Setting Optimal Thresholds for Each Unit

Within approximately 4 weeks after installation*, AI automatically learns the specifics of each unit.
It then sets the most suitable threshold for each one. By relying on precise, data-driven threshold settings instead of human intuition, false alarms and related losses are significantly reduced.

• * For 24-hour operation

Intuitive GUI also displays causes and corrective solutions

Since motor status is displayed with diagrams and an array of colors, even first-time users can understand it intuitively
When signs of malfunction are detected, it shows the location of the cause as well as the recommended corrective solution.

24/7 Monitoring of Nine Motor Areas for Predictive Maintenance

• Power system
• Shaft balance
• Alignment
• Bearings
• Air gap
• Cooling system
• Rotor
• Stator winding
• Mechanical slack

The system also detects electrical anomalies that trigger mechanical problems such as sound or vibration.
This helps to prevent unplanned downtime before it occurs. The status can be monitored 24/7, 365 days a year,
enabling a shift to CbM (Condition-Based Maintenance )to ensure that equipment maintenance can be performed in a planned and efficient manner.

How SMS Works

How are Anomalies Detected with Such High Accuracy?

1. Motor information
2. Initial learning data (approx. 4 weeks) *during 24-hour operation
3. Automatic generation of anomaly detection algorithm

SMS Overview

Supported Motors

• Three-phase induction squirrel-cage motors
• Standard low-voltage IEC or NEMA motors
• Motors with frame size ≤ 450 (IEC 60034) or 500 (NEMA MG1) and output range 0.37kW–500kW
• Direct drive, inverter drive

Operating Conditions

Specifications

Conformance standards

Dimensions

Real-World Implementation

Real-world Implementation in the Painting Processes for Vehicle Bodies

Importance of Symptom Management in the Painting Process

In the automotive production process, painting is the most energy-intensive process.
Specifically, the painting process is estimated to account for about 70% of the total energy cost in a vehicle body plant.
This high cost is largely due to the extensive use of pumps for applying paint to the body, as well as the fans required to remove evaporated solvents, paint particles, and regulated pollutants.
Because many pumps and fans must operate continuously in the painting process and cannot be shut down, predictive monitoring is becoming increasingly important.
The Smart Motor Sensor offers an ideal solution for predictive monitoring in the painting process by continuously monitoring motors at 40-minute intervals, detecting abnormal vibrations on the load side, and issuing warnings.

Production and processing

Benefits of Introducing SMS

• Reduces unplanned downtime; increases monitoring frequency (monitors in 40-minute cycles)
• No need for human walkaround inspections and monitoring work
• No need for vibration measurement and analysis work
• Minimizes necessary maintenance / Optimizes bearing replacement timing
• Maintenance can be performed while problems are still minor, extending equipment life

Supported equipment

Car Body Painting Process

Hundreds of pumps and fans are used in pretreatment and post-treatment.

Smart Motor Sensor System

4 AA lithium batteries, over 1-year life, user-replaceable (IP65/67 support planned)
Learning doesn't require a new motor; as long as it operates normally without unusual noise, that condition is established as the baseline, and any subsequent deterioration is diagnosed by comparison.