Condition Monitoring of Electric Motors using MCSA

In today’s competitive manufacturing landscape, unplanned downtime is the single biggest threat to productivity and profitability. Electric motors drive critical processes across industries, yet even minor, undetected faults can trigger costly stoppages.

Our Solution: Motor Current Signature Analysis (MCSA) — a non-invasive, real-time monitoring system that transforms raw electrical current into actionable intelligence, keeping your motors healthy and your operations uninterrupted.

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Watch How MCSA Works

Why MCSA?

Non-Invasive: No additional vibration sensors or machine disassembly required.
Comprehensive Coverage: Detects both electrical and mechanical issues from a single data source.
Fast Deployment: Clamp-on installation at MCC/VFD panels — no production stoppage.
Scalable: One solution for hundreds of motors across multiple plants.

Real-Time Monitoring

Current signals are continuously captured and streamed to your control room, empowering engineers with live, actionable insights.

Waveform & Anomaly Detection

Subtle waveform variations are analyzed using AI/ML models to detect anomalies invisible to manual observation.

Frequency Analysis (FFT)

Fast Fourier Transform converts current data into frequency signatures, revealing fault-specific peaks linked to mechanical or electrical issues.

Pinpointing Faults

MCSA identifies bearing wear, rotor bar cracks, eccentricity, misalignment, and unbalance — all without physical inspection.

Health Index Visualization

A simple green–yellow–red scoring system communicates motor health at a glance, enabling fast and confident decision-making.

Business Impact

Minimize unplanned downtime with early fault detection.
Reduce maintenance costs by shifting from reactive to predictive strategies.
Extend motor life through continuous condition tracking.
Optimize asset utilization with comparative insights across fleets of motors.

Dashboard & Insights

With MCSA, every motor becomes a data-driven asset. Transform maintenance from guesswork into foresight — unlock the intelligence that powers industry.