Research & Best Practices

Motor Condition Monitoring Sensors


Identifying the earliest warning signs of an impending breakdown is one of the most effective methods for manufacturers to reduce downtime, improve maintenance efficacy and boost overall productivity. How can facilities detect these signs early enough to make a difference? With motor condition sensors, which can closely track equipment performance and provide real-time alerts for even the smallest fluctuations in component functionality — early indicators that maintenance may be required soon.

Putting data to work for improved maintenance

Motor condition monitoring sensors are used for all types of rotating equipment, implementing detection practices such as motor vibration monitoring, temperature monitoring, vibration monitoring and more. A sensor-equipped motor health monitoring system can then help technicians investigate and address maintenance issues at low-impact times for the facility.

Motor condition monitoring tools can be used for any type of equipment that uses motors, including:

  • Pumps
  • Compressors
  • Fans
  • Blowers
  • Turbines
  • Gearboxes
  • Generators
  • And more

Operational benefits of predictive technology

Extended machinery life

By addressing maintenance issues before they lead to breakdowns, a motor condition monitoring system can help reduce or eliminate catastrophic failures — the type that produce massive and unplanned wear and tear on your equipment investments. By taking action when problems are just beginning, you can help extend equipment service life and lower your maintenance costs.

Reduced maintenance workload

Predictive maintenance is an effective supplement to scheduled preventive maintenance, but it also solves one of the primary inefficiencies of that tactic — namely, that with a preventive approach, maintenance issues are addressed only when they occur. In addition, predictive maintenance with motor condition monitoring facilitates early maintenance to solve potentially big problems, rather than the all-hands-on-deck scenarios that unplanned breakdowns often entail.

Streamlined inventory management

Motor condition monitoring with sensors provides a wealth of data that, over time, can give you a deep level of insight into your actual maintenance needs. With this data on hand, you can forecast inventory needs more accurately and efficiently. This can help reduce the number of “just in case” parts collecting dust on your shelves while ensuring that the spares you need are there when you need them.

Consistent product quality

Sensors for motor condition monitoring are designed to detect even the smallest fluctuations in equipment performance — fluctuations that, even if they don’t lead to maintenance events, could lead to variance in part consistency and quality. By drawing on real-time and historical sensor data, your facility can fine-tune operations to increase quality levels, streamline QC and add value for customers.

Industries served

Focused, yet flexible across multiple industries

Our MRO and outsourced industrial maintenance services focus on eight key industries across manufacturing. With this expertise on hand, we are ready to adapt to new industries, production assets and manufacturing environments. With over three decades of experience, we are uniquely equipped to address your manufacturing and maintenance challenges to improve operational productivity.

The ATS difference

At ATS, we draw on our decades of experience in data- and technology-driven solutions to make every implementation as seamless and effective as possible for you. Our R360™ Machine Health Monitoring was carefully designed to provide the biggest and fastest impact and return on your investment, with unique benefits such as:

  • Constant, 24/7/365 monitoring of indicators such as vibration and temperature to help predict and prevent machine failures and unplanned downtime
  • Fully wireless data acquisition and transmission, requiring no external power or network access
  • ATS installs sensors for you, with no internal resources required on your part
  • ATS sensors are magnetized and do not require mounting hardware
  • Your machines do not have to stop for ATS to install sensors
  • A full reading is done eight times per day (every 3 hours)

This level of service can lead to fast improvements in uptime through our Reliability 360® Technology Center and a positive ROI.

ATS machinery in a factory

Protect against downtime

Are you looking for a data-driven predictive maintenance program that gives you the insight and analytics to proactively reduce unplanned downtime? ATS can help.

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