MCSA – Motor Current Signature

Analysis
Using IoT & Data Analytics

AVL India Private Limited, Chennai Public

Industry 4.0 – Interplay of three major competencies

Data
Measurement
Sensors, Controllers

Data
Transmission Software &
IoT devices, Networks, Data
Edge Analytics Analytics

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 Daksh Manufacturing Suite – Bouquet of Curated Modules on One Platform

Process
1 Production OEE Traceability
Traceability
Planning efficiency

Motor Current
Maintenance Condition Asset
2 Maintenance Manager Monitoring Monitoring
Signature
Analysis

Relay &
3 Utilities EMS BMS Breaker
Fuel & Water
Management
monitoring

Manufacturing Suite 4 Safety PPE

Human
intrusion
Identification detection

5 Supply Chain Inventory Inbound

Management Tracking
Standard Solutions

Anomaly
6 Quality Detection
Fool proofing Customized Solution

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MCSA – Motor Current Signature Analysis

MCSA is a relatively new condition monitoring methodology. It’s a

FFT analysis of current drawn by electric motor and identify the
changes in its sine wave formation.

As electric motors are major prime mover for all equipment in

industry, any fault in the equipment directly affects the motor current
Rotor Faults - 10% signatures (behavior). The changes in the sine wave formation can be
Stator Faults - 30-40% recorded and analyzed to pinpoint the fault and its cause before it
Bearing Faults - 40% results in failure.

Eccentricity Faults – 10%* By analyzing the current spectrum, We can identify the faults,
Power Circuit Faults -10* cause and report to user with remedial action suggestions
•Power Quality
•Insulation
•Capacitor

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MCSA – Motor Current Signature Analysis

Motor current signature analysis (MCSA) is a diagnostic technique used to assess the condition of
electrical motors. The technique involves analyzing the current waveform of the motor during operation
and identifying any deviations from the expected signature.

The current signature of a motor changes with variations in load, speed, and torque, as well as with
changes in the condition of the motor, such as bearing wear, rotor bar defects, and winding faults. By
analyzing the current signature, it is possible to detect these types of faults early and predict when they
are likely to lead to motor failure.

MCSA can be performed either online or offline. Online MCSA involves monitoring the motor current in
real-time during operation, while offline MCSA involves analyzing recorded data from a motor after it has
been shut down.

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Outcome
1. Analyzing current signatures for detecting various faults in induction motor using signal
processing methods

2. Predictive maintenance use-case to predict failures in a motor

3. Raise alerts and mobile notification in case of a fault detection

Approach
1. Analyzing the change in the motor supply current

2. Distinguish between various motor problems such as looseness, misalignment and so on

3. Indicating the health status of the equipment on frontend dashboard

4. Sending mobile notifications to the respective users

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Benefits

1. We can eliminate the need of costly vibration sensors, hardware and use simple current
transformers and thus making it highly cost effective

2. With a smaller number of hardware involved, deployment time is drastically reduced

3. MCSA can also capture all other issues related to electrical supply parameters which
vibration CMS cannot do.

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Data Analytics & Machine Learning

• Daksh – a modular, data intelligence IOT platform

• Analytics layer provides great flexibility to build, test and deploy

powerful data science models for targeted use-cases
App Layer
• Easy integration with state-of-the-art machine learning and deep
learning algorithms for real-time forecasting (time-series models)
Analytics Layer API Layer
example use-cases: anomaly detection, energy demand forecasting

• Model predictions available on front-end plots along with real-values Database Layer
for monitor post-deployment.
:
• Support for use-case discovery, definition, training and deployment on :
Daksh. Support could include long-term model maintenance,
continuous training and enhancement.

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DAKSH IoT Architecture

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Software & Hardware Standards - Compliance

Reports Compliant to ISO 50001

Software Compliant to ISO 27001

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Customized Applications

Daksh platform is capable of processing large amount of data and customize the data
analytics for any specific requirements in the domain of Industry 4.0, IIoT, Digitalization &
Process Automation.

Please share your specific Use case / Needs / Pain areas for any process , we will be very
happy to propose a complete technical solution for your unique requirement.

sridharan@avl.com

9551414375

www.Dakshiiot.com

AVL India Pvt. Ltd

2-2A, AMG Towers, 2nd floor,
No: 28, Lawyer Jagannathan
Street,
Alandur, Chennai – 600016,
Tamil Nadu.
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Thank you

www.avl.com

Public