Motors Enter the IIoT Space via Smartphones and Add-on Sensors

Preventative maintenance software for electric motors has been available for years, but has recently taken a huge step in its evolution. Along with other “smart” automation machinery, motors have entered the realm of IIoT. A host of embedded sensors are usually required in order to generate big data for Cloud-based monitoring of rotating machinery via an AC drive or motor controller. Additionally, form factor issues arise at certain frame sizes, limiting the sensor-laden solution to larger powered motors. The simple induction motor that has remained relatively unchanged for over a hundred years, is now able to circumvent this wire-bound sensor solution in limitless fashion, and enter the Internet-connected factory without costly alteration or mechanical upgrades. ABB recently unveiled a Bluetooth-enabled device the size of a credit card and less than 1/3” thick that can be attached directly onto the motor’s housing, transmitting real-time data to a smartphone. According to ABB, this device will be available for around $50, and can be attached to motors of all sizes, power ranges, and voltages. It can also be attached to motors that have been installed in the field for decades. This technology provides a relatively low-cost foundation for a modern asset management strategy that will add to the inherent efficiency of the motor, as well as extending its operating life. Both these benefits working in tandem will significantly lower the total cost of ownership of the motor and provide a very compelling value proposition for owner/operators. The attachable device transmits data on temperature and vibration of the motor, two important condition parameters that AC drive-enabled motors and other remote monitoring solutions cannot provide. An additional benefit is that the device can provide load variance data, providing data-driven justification for the addition of a further efficiency-enhancing AC drive. Data produced by the ABB device remains in a mobile application for now, separate from the network into which motor data is fed from the AC drive or motor controller. A Wi-Fi bridge will be needed to unify these separate data streams for a complete analysis of the motor. At this time, ABB is the only motor supplier that has announced a sensor-less solution for condition monitoring and is scheduled to introduce this product to the US in late 2016, and the European Union in 2017. In ARC’s recently published report on Low Voltage Motors, our global market analysis for 2015 takes an extensive look at four major regional motor markets and several key motor segments including Power Rating and Efficiency Class. In addition, the report includes over 20 industrial segments across 22 vertical machinery sectors to assess growth and the dollar value of the motor market in each sector. Forecasts are provided through 2020.  This research confirms the rapid adoption of IIoT enabled services and the role that industrial automation components factor into this evolution.