Condition Monitoring and Predictive Maintenance of Electric Motors

In the context of SPS Nuremberg, WEG presented a new gateway and updated models of advanced inverters, expanding the possibilities of developments and applications. Thanks to these solutions, it is also possible to monitor the health of electric motors on an industrial scale.

by Marcello Ponte

WEG presented a new gateway for WEG Motor Scan as a highlight at SPS Nuremberg 2019. The condition monitoring solution presented last year as a retrofit option enables real-time monitoring of WEG electric motors for predictive maintenance purposes.
The collected data can now be transferred to a secure cloud using gateway technology, in addition to the previous option of using a smart device app with Bluetooth. Users can access the data in the cloud through the app or the WEG IoT Platform web portal.
This enables detailed analysis of the monitored motors. Additional highlights include the updated CFW500 and MW500 variable speed drives.

Operational data acquired automatically
WEG Motor Scan is an easy and cost-effective solution for predictive maintenance measures that lead to extended service life and higher plant availability. The gateway enables users to automatically collect data from WEG Motor Scan sensors, eliminating the intermediate step with the mobile app. The gateway complements the existing mobile app and acts as a router that captures all installed sensors within a range of approximately 30 m in an industrial environment.

Inverters for demanding manufacturing environments
There are some innovations in the CFW family of variable speed drives: the new CFW500 IP66 in frame sizes A and B covers motor power ratings from 250 W to 15 kW.
These variable speed drives can operate over a wide voltage range of 200 to 240 V, 380 to 485 V or 500 to 600 V, and they can be deployed at ambient temperatures from -10° to +40° C. Their great sturdiness and high protection rating make them a good choice for demanding manufacturing environments.
Furthermore, the CFW500 range is extended to frame size F with a rated power range up to 55 kW. The new CFW500 operates in the voltage range of 380 to 480 V, opening new deployment options for users in the higher power range for a large number of industrial applications – in particular general mechanical engineering for conveying, turning, lifting, pumping and ventilation.
The new power class extends the main deployment areas of the CFW500 in small and micro applications.

An economical, flexible solution for reducing risks
Integrated Safe Torque Off (STO) and Safe Stop 1 (SS1) safety functions give mechanical engineers an economical and flexible solution for reducing risks arising from unexpected and unforeseen events.
This includes prevention of unintentional machine starts, emergency shutdowns, and controlled stops.
Another integrated function is PumpGenius for pump control, which enables precise pressure and/or flow control during the entire process cycle. With a convenient programming wizard, PumpGenius helps to minimize downtime.

No need for long cables and switch cabinets
The MW500 variable speed drive, designed for decentralised deployment, has also been updated. It is now available for lower power levels in the range of 370 W to 2.2 kW and is being launched for 380 to 400 V mains voltage in frame sizes A and B. A sturdy housing design with protection rating IP66 or NEMA 4X allows the variable speed drives to be mounted directly on the motor terminal box or on the wall using an adapter plate.
This eliminates the need for a motor
feed cable and switch cabinet, reducing complexity and costs for installation and commissioning. The MW500 can handle a 150% overload for 60 seconds every 10 minutes and can operate at ambient temperatures up to 40° with wall mounting or 50° C with motor mounting.
Designed for decentralised deployment, these variable speed drives can be used for a broad range of applications, such as pumps or fans. l