Seven independent analysis dimensions, a traffic-light colour code, an operational technical report. All from a single measurement of the motor's electrical signature — no sensors on the machine, no plant shutdown, no physical access to the rotating parts.
Rather than fitting accelerometers or probes to the machine, we read the electrical signal already flowing through the motor's supply cable. It carries far more information than most people realise.
When an AC electric motor is running, the drawn current and supply voltage contain much more than instantaneous power: they carry the "signature" of everything happening mechanically and hydraulically on the driven machine. A deteriorating bearing modulates the current at a specific frequency. An impeller in cavitation produces a clearly recognisable high-frequency spectrum. A coupling misalignment causes harmonics to appear at precise positions.
Our instrumentation captures these signals via current transformers and voltage probes fitted at the motor's electrical distribution panel — metres away from the machine itself, often in the switchroom. From there it is all signal processing and machine learning, trained on the Artesis dataset of over ten million real motors collected over 25 years of worldwide operations.
The practical implication is significant: with a single accessible measurement point (the MCC panel), we can diagnose submersible pumps at 150 metres' depth, motors in ATEX zones, or assets confined in hazardous environments — without fitting accelerometers to the rotating parts, without shutting down the plant, without any physical access.
The asset runs normally: no shutdown, no bypass, no special switching procedure.
Current transformers and voltage probes connected to the motor cables — a few minutes' work.
The portable system records ~7 minutes of high-resolution electrical signature: voltage, current, power, power factor.
Automatic diagnosis across 7 dimensions, traffic-light colour code, documented operational recommendations.
No accelerometers, no wiring, no sensor maintenance — sensors themselves can fail. Everything from the MCC panel.
Typical acquisition time for one machine. Enables campaigns of up to 20 motors per day with a single field technician.
The algorithm classifies anomalies by comparing your motor's signature against a population dataset far larger than any single asset.
Every asset is evaluated across seven independent dimensions, each rated with a colour code (green / yellow / red) for intervention priority. Click to read the detail of each one.
Mechanical looseness, non-rigid baseplate, anchoring problems.
Loose Foundation detected at Caution status on Marconi P.Industriale 1, Selva P2 KSB and Via Gentile P2: the signature indicates mechanical play at the baseplate or yielding anchors. Operational recommendation: check tightness of foundation bolts and verify structural rigidity before the next scheduled shutdown.
A yielding foundation amplifies the vibrations the motor transmits to the system, accelerating wear on bearings, seals and couplings. It is often a problem fixable in a few hours at very low cost — but left unaddressed it cascades into far more expensive components.
Rotor imbalance, loss of dynamic balance.
Current imbalance 1.73% detected on Via Gentile P2 — the highest value in the analysed fleet (from a single AMT Pro measurement). Below the critical threshold of 5% but to be monitored in subsequent periodic measurements: growth beyond 2.5% would signal active mechanical or electrical deterioration.
Unbalance generates radial forces that wear down bearings and seals. It can be resolved with a scheduled rebalancing job — typically a few hours' work, achievable within existing planned shutdown windows, without any unscheduled stoppages.
Coupling misalignment, belt and pulley wear, drivetrain problems.
On Pump1 at a pumping station: the Transmission/Driven Equipment band shows recurring spikes, typical of water-borne debris striking the pump impeller. Continuous monitoring clearly distinguishes these transient events (impacts) from sustained structural deterioration (belt/coupling wear). Recommendation: inspect the upstream filtration system.
A misaligned or worn transmission can reduce efficiency by up to 5% over time, and generates vibrations that propagate throughout the system. It is often the first "bridge" through which a small problem becomes a major failure.
Outer race defects (BPFO), inner race (BPFI), balls and cage (FTF).
On Pump3 at a pumping station: BPFO + BPFI + FTF all confirmed on bearing model 6213 — the signature is clear and growing over time (4 months of continuous trend). The system has already estimated time-to-failure at a confidence level sufficient to schedule the intervention at the next planned shutdown, avoiding unplanned stoppages.
Bearings are the single component responsible for the most failures in AC motors and pumps. Identifying them months in advance means: bearing replaced during a planned 30-minute shutdown vs destroyed rotor due to overheating after 8 hours of unplanned downtime.
Broken rotor bars, end rings, static and dynamic eccentricity.
No active rotor fault detected across the glassworks fleet — a sign that assets are well maintained from an electromechanical standpoint. All identified issues (€54,000/year in excess costs + 77 t CO₂/year) are concentrated in transmission, bearings, foundations and efficiency optimisation, not rotor problems.
A rotor failure is a catastrophic event: the motor trips on thermal protection due to overheating, and in the worst cases the stator insulation is destroyed. Early diagnosis makes the difference between "replace rotor" and "buy a new motor".
Insulation degradation, inter-turn short circuits, voltage imbalances.
No pump in the analysed fleet shows an active rotor/stator signature. Voltage imbalances ≤0.10% and current THD <2% across the entire fleet — the network upstream of the inverters is healthy, and no motor shows imminent stator problems. All identified faults are mechanical-hydraulic in nature.
Stator problems are slow but irreversible: once the insulation has degraded there is no going back. Early detection enables a structured rewind to be planned, rather than reacting to a sudden failure.
Cavitation, blockages, discharge and suction obstructions, motor overload.
On Pump2: active cavitation confirmed by PSD spectral analysis in the 1,800–3,000 Hz band, with a worsening trend observed over 4 months of monitoring. A discharge obstruction event was captured live on 9 January 2026 — a valuable timestamp for intervention planning. Operational recommendation: check available NPSH and inspect impeller and volute.
On one civil water pump: 110% of the motor's nameplate load. If sustained, this condition accelerates bearing and seal wear in a non-linear fashion and stresses the stator insulation. Recommendation: shut down at the first opportunity, verify hydraulic sizing and carry out a full inspection.
Hydraulic anomalies are the most common faults in pumping and ventilation systems, and often the ones with the greatest impact on energy consumption. A pump operating at 59% of BEP can consume 15–20% more than necessary — and that 15–20% is exactly the efficiency margin recoverable with a targeted intervention (impeller trim, resizing, process adjustment).
The Artesis report rates every dimension on a traffic-light scale. It is the fastest way for anyone managing a motor fleet to see where action is needed and where it is not — without needing to be a spectral signature specialist.
Operational advantage: the maintenance manager opens the report and within 30 seconds knows which assets are red-priority, which are under observation and which are "clean". No spectral interpretation required, no PhD in vibration analysis. Just decisions.
At the end of the check-up the client receives a technical document structured to answer the real operational questions a maintenance manager faces — not the academic ones of a scientific conference.
The bar chart showing the 7 dimensions rated green / yellow / red. Below: the automatic diagnosis referencing dimensions in caution and the recommended corrective actions. This is the first page anyone looks at in the report.
Motor nameplate data (make, efficiency class, annual running hours) and a comparison of rated vs measured values for voltage, current, power, power factor, RPM and efficiency. Below: total energy consumption and annual cost.
A table quantifying for each detected anomaly the energy impact in kWh/year and the additional cost in €/year. This is the page you take into the boardroom to present to the CFO: concrete numbers, not promises.
Comparison between the existing motor and IE3 / IE4 high-efficiency alternatives, including calculation of annual energy savings, avoidable annual cost and CO₂ emission reduction. This is where the diagnosis becomes a documented investment case.
The check-up is the starting point. The subsequent phases are independent and are only activated if the data from the previous phase justifies them. No upfront commitment to later phases.
In-depth assessment of motors, pumps and fans with AMT Pro. Technical report with actual condition and operational recommendations. Documented baseline that serves as a reference for every future decision.
Repeated advanced diagnostics over time with AMT Pro (typically every 6 months). Historical trends to distinguish transient symptoms from real deterioration. Up to 20 motors per day with a single field technician.
Fixed e-MCM system installed at the panel on the most critical assets, with a self-learning digital twin. Real-time alarms for cavitation, bearings and electrical anomalies. SCADA / BMS / remote-control integration.
A free, no-obligation 30-minute introductory call with one of our engineers. We review your plant together, assess the potential and propose the check-up best suited to the number and criticality of your assets.