KofKaN Smart Motor Monitor
Industrial motor condition monitoring system
Overview
Motors rarely fail without warning — they run hotter, draw more current or vibrate differently first. Smart Motor Monitor is our condition monitoring design: a sensing node clamped to an industrial motor that watches vibration, casing temperature, current draw and runtime, extracts features on the device, and raises an alert when behaviour drifts from its own established baseline. It is aimed at small and mid-sized operations that run reactive maintenance today and want early warning without a full predictive-maintenance contract.
System capabilities
Vibration analysis
Three-axis sampling with RMS and peak features computed on the node rather than streamed raw.
Thermal monitoring
Casing and bearing-area temperature tracked against the motor's own normal operating envelope.
Current signature
Running current observed for load changes, phase imbalance and starting anomalies.
Runtime accounting
Operating hours and duty cycle logged to support service intervals based on real use.
Baseline learning
Each motor's healthy signature is captured at commissioning and stored for later comparison.
Event-driven alerts
The node stays quiet until a threshold or trend trips, which keeps power and bandwidth low.
How it works
- 01Sensors mounted on the motor capture vibration, temperature and current
- 02Embedded controller extracts features from short sample bursts
- 03Values are compared against the stored healthy baseline
- 04Deviations publish an alert with motor ID and severity
- 05Maintenance dashboard aggregates events across the site
Applications
- Manufacturing lines
- Pumping stations
- Industrial facilities
- Workshops and machine shops
- Maintenance planning
Gallery
Image credits
- Silniki by Zureks — Zureks (CC BY-SA 3.0)
- Induction-motor-1 — MikeRun (CC BY-SA 4.0)
- Alaska Air National Guard Staff — U.S. Air Force (CC0 1.0)