When the motor is running but no one knows how well
A motor can run hot, trip or use more energy than expected for reasons in the motor, converter, supply, driven process or operating pattern. We assess the complete chain under actual duty.
A running motor is not necessarily operating correctly
Nameplate data describes rated conditions, not the actual operating point. Temperature, current and energy use must be interpreted together with load, cooling, supply and duty cycle.
Replacing the motor alone may leave the real cause untouched if the problem is in the driven process, control strategy or electrical supply.
Heat or repeated trips
The motor or converter runs hot, alarms or trips without an established cause.
Unexpected energy use
Consumption is high in relation to useful process output or varies without explanation.
Change of equipment or duty
A replacement, speed control or process change needs to be assessed against actual operating conditions.
Motor, drive and electrical supply in one context
The scope follows the energy flow from the supply to useful mechanical work and the stresses acting on each part.
Loading and operating point
Measured power and process data show whether the motor is oversized, overloaded or operating away from its intended point.
- Actual load
- Operating point
- Mechanical demand
Temperature and cooling
Thermal images and temperature trends are interpreted with load, ambient conditions and cooling path.
- Temperature rise
- Cooling conditions
- Thermal trend
Duty cycle and starts
Start frequency, acceleration and changing duty can create stress not visible in average current.
- Start sequence
- Duty cycle
- Transient loading
Voltage quality and phase balance
Supply voltage, unbalance and phase loading affect torque, losses and temperature.
- Voltage level
- Unbalance
- Phase loading
Converter and harmonic currents
Waveform, switching and harmonic current are assessed in relation to motor design, cabling and control.
- Harmonic spectrum
- Converter operation
- Cable and motor stress
Efficiency and losses
Electrical input, mechanical demand and operating time show where improvement can produce useful effect.
- Loss distribution
- Part-load operation
- Improvement potential
A disturbance in one part affects the whole chain
A process restriction can increase motor load; an unsuitable control strategy can create repeated starts; supply unbalance can increase losses and temperature. The measured symptom must therefore be traced through the system.
The right action may be electrical, mechanical, operational or a combination.
Voltage, protection, cabling and converter input.
Converter, motor, coupling, gearing and bearings.
Flow, pressure, speed, load and operating demand.
From measurement to verified action
The assignment is designed around the symptom, process requirement and decision that must be made.
Map and measure
We document the drive train and record representative operation.
- Map: Ratings, control, process, duty and previous events.
- Measure: Electrical quantities, temperature and relevant process values.
- Analyse: Relate stress and losses to actual duty.
Act and verify
Measures are prioritised by technical effect, reliability and feasibility.
- Specify: Operating, control, electrical or equipment changes.
- Implement: CLEPS performs or coordinates agreed work in Sweden.
- Verify: Repeat measurements under comparable operating conditions.
Technical evidence for the right action in the right order
The delivery separates the measured operating point from assumptions based on nameplate values or nominal process data.
Depending on scope, it may include:
- Measured electrical and process operating points
- Load, duty-cycle and start analysis
- Temperature and cooling assessment
- Power-quality and converter findings
- Loss and efficiency assessment
- Documented uncertainty and limitations
- Prioritised measures
- Verification plan
Findings are located in the chain rather than attributed to the motor by default.
Nameplate values are compared with measured operation and process demand.
The result must be traceable after the measure
Comparable measurements show whether temperature, loading, energy use or reliability changed as intended. Where duty varies over time, continued monitoring can show whether the improvement remains valid.
Motor data in actual operation
Start with the motor that is causing concern
Tell us what you observe, how the equipment is operated and what has already been checked. CLEPS works in Sweden; availability and delivery terms are confirmed in the quotation.
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