Smarter Motor Monitoring: How Malloy Electric Leverages VFD Data for Predictive Maintenance
Smarter Motor Monitoring: How Malloy Electric Leverages VFD Data for Predictive Maintenance
At Malloy Electric, understanding motor drive systems isn’t just a capability—it’s a core strength. As highlighted in a recent technical paper by Carl Tolbert, senior application engineer at Malloy, the company is at the forefront of applying variable frequency drive (VFD) technology for smarter, cost-effective industrial maintenance.
Rather than relying on traditional, sensor-heavy methods of nondestructive testing (NDT) or predictive maintenance, Malloy champions a more integrated approach: using the built-in diagnostics of modern VFDs to monitor motor health in real-time. These drives already track key performance metrics like torque, speed, current, and energy usage—data that can be mined for early signs of mechanical wear, misalignment, or power quality issues.
What makes Malloy’s approach standout is its practical implementation. By using VFDs such as the ABB ACS880, engineers can remotely access this rich data via standard protocols (like Modbus TCP/IP), feeding it into customizable PLC/HMI-based dashboards. This opens up the potential for trend tracking, real-time alerts, and even AI-powered predictions of equipment failure—without additional sensors or hardware.
Malloy’s knowledge of VFD systems bridges the gap between electrical diagnostics and mechanical reliability. Their work points to a future where motor systems are not only smarter but more resilient—thanks to the data they already generate.
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