World leader in predictive maintenance for electric motors

ADI OtoSense Smart Motor Sensor is an AI-based, full turnkey hardware and software solution for condition-based monitoring.
  • No expert analysis required
  • 9 Mechanical and electrical faults detected
  • No wires, no gateways
  • Quick to deploy
  • No expert analysis required
  • 9 Mechanical and electrical faults detected
  • No wires, no gateways
  • Quick to deploy

Overview

More than just a sensor

ADI OtoSense Smart Motor Sensor (SMS) monitors the condition of your electric motors by combining best-in-class sensing technologies with leading-edge data analysis. ADI OtoSense SMS detects anomalies and defects in equipment, enabling you to forecast maintenance cycles and avoid unplanned downtime.

Agnostic of motor type, ADI OtoSense SMS covers the most critical diagnostics, translating data into actionable insights. The Smart Motor Sensor allows for 24/7 condition-based monitoring of all your low voltage electric motors. It presents information in a clear way, telling you both what the problem is and how to fix it.

Dashboard

Get a complete overview of your machine health diagnosis and fault detection with detailed information and visualization of each motor's status.

Mobile application

The ADI OtoSense SMS App allows easy setup of your Smart Motor Sensors, visibility on deployment data, and in-app notifications and alerts on critical events.

Benefits

Rethink your predictive
maintenance strategy

ADI OtoSense SMS optimizes your production environment and reduces breakdowns using robust condition-based monitoring hardware and software. Realize benefits such as lowering asset maintenance costs, extending equipment life, and increasing uptime.

Monitor in realtime

Monitor your equipment more frequently to know when mechanical and electrical failures start to occur and how these issues impact your production process.

Take action

A unique model is created for each motor to deliver optimized diagnostics that align with the process. The Smart Motor Sensor provides information you can use to not only diagnose the problem but know the severity so maintenance teams can take action.

Optimize business

By continuously monitoring your motor performance and health, you will have better visibility into maintenance and spare parts needs to know what to order and when to order, reducing inventory costs.

Identified fault types

Sensing interpretation at its best

ADI OtoSense Smart Motor Sensor (SMS) is the most accurate solution on the market to sense and interpret your machine data. This is why we define ourselves as a sensing interpretation world leader. The SMS can detect the following failures:

  • Power system

    Asymetry in motor currents

    Faults caused in the motor power system that can cause an asymmetry in the motor currents. For example, loss of a phase or change in the impedance of power cables.

  • Motor shaft/Balance

    Gravity center displacement

    Machine rotor unbalance as a consequence of the gravity center displacement of any of the motor rotating parts. For example, accumulation of dust on the motor fan, loss of balance parts of the rotor, mismatch of the coupling plate, flexed shaft.

  • Alignment

    Motor/load misaligned

    Loss of alignment between motor and motor load.

  • Stator winding

    Stator resistance variation

    Faults caused in the motor stator, may cause an asymmetry in the motor currents. For example, variation of the impedance of one of the motor phases.

  • Eccentricity

    Stator/rotor concentricity issue

    Malfunction of the motor when the concentricity between the stator and the rotor is not maintained. The reasons can be a bent rotor shaft on large machines or a tilted shaft as a result of poor bearing installation.

  • Cooling system

    Motor cooling system problem

    Problems in the motor cooling system, such as obstruction of the ventilation outlet or the fan stop, in case of independent ventilation of the motor.

  • Rotor

    Rotor resistance variation

    Rotor failures such as discontinuities in the active part of the rotor, such as rotor bars or short-circuit ring, or problems in the welds of the copper rotor. These problems usually occur in motors that start and stop very frequently and with high loads.

  • Bearing

    Failures/defects in bearing

    Bearing failures such as lack of lubrication or defects in the inner and outer race, the cages or the rolling elements. The reasons for the origin of these failures can be: lack of maintenance of the bearing, poor installation of the bearing, unsuitable operating conditions, electrical currents in the bearings, ...

  • Soft/Loose foot

    Fixing system problems

    Problems in the fixing system of the motor to the operating bench.

Performance

This performance indicator identifies potential systemic issues that are indicative of a load problem or process change that might require further action on the system and manufacturing process.

How it works

Simple to deploy,
24/7 condition based monitoring

01

Set up

Configure the ADI OtoSense SMS using the iOS/Android app. Deploy the Smart Motor Sensor within minutes, even while your motor is still running.

02

Learn

Once the sensor is set up on the motor and is commisioned, the learning process has started. Leave sensor running during normal operation conditions.

03

Receive alerts

View your alerts in the mobile app or the web dashboard. This allows you to prevent any electric motor failures.

Download our app

ADI OtoSense SMS documentation

REST API

Integration made easy

Our developer-friendly API allows you to integrate ADI OtoSense SMS insights directly into your platform to build action orientated systems with ease.

Get Started

Testimonials

Trusted by experts

Marçal Gotanegra
CMO Maintenance Manager at Corbion

With the technology of ADI Otosense and in particular with the SMS, we manage to eliminate manual routes of predictive maintenance guaranteeing the reading of data of critical equipment that are not always working, we obtain very detailed and reliable information of the state of the machine, and we are more efficient with our maintenance staff dedicated to accurate diagnostic fault repairs.

Marçal Gotanegra
CMO Maintenance Manager at Corbion
Marçal Gotanegra
CMO Maintenance Manager at Corbion
Gonzalo Gracia De La Rosa
Maintenance plant manager, Naturgy

The SMS device from ADI Otosense, allows us to efficiently monitor the motors of important machines in our power generation process, such as gas turbine cooling fans, hydraulic oil control pumps or closed circuit refrigeration pumps. In this way we eliminate preventive work and optimize the measurement of manual vibrations, saving man-hours of maintenance and preventing operators from accessing dangerous places or high elevations.

Gonzalo Gracia De La Rosa
Maintenance plant manager, Naturgy
Gonzalo Gracia De La Rosa
Maintenance plant manager, Naturgy

Partner program

Our business is to enable yours

You understand your customers and their needs better than anyone else. With ADI OtoSense’s tailored partner solution, we provide you with a complete ecosystem that includes branded hardware, software and mobile apps. Deepen your customer relationships by monitoring their assets in real-time and transform your business by expanding your services. ADI OtoSense helps you deliver even more value.

Become a partner
  • With the Smart Motor Sensor solution, we help companies minimize their production stoppages or risks and maximize their profitability by preventing their electric motors' failures. Smart Motor Sensor facilitates a better understanding of electric motors' condition and behaviour, and early detection makes it possible to act quickly. Smart Motor Sensor monitoring in real-time allows our customers to understand their motors' behaviour from a distance.

    Roger Viera
    Co-Founder Shareholder, Reflexes Tech
  • As the owner of an Electric motor repair shop, I experienced the daily struggle I had with resources. If we only had eyes and ears in all those electric motors, we would know what state they were in. With Smart Motor Sensor, we can provide proactive maintenance based on live data. We are now able to offer the knowledge of experienced drivetrain engineers on demand. Smart Motor Sensor provided by Analog Devices is the game-changer solution I was looking for.

    Joris Bracke
    Smart Motor Services BV owner

Security

Secure by design, end to end

ADI OtoSense SMS is designed from end to end with industry-best security protocols and controls, which ensure that SMS data and insights maintain their accuracy and precision, are reliably processed and transmitted with no interruptions, and are always and only accessible by authorized OtoSense SMS users.

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Customer data management

Strict partitioning and restricted access

Each SMS customer has a dedicated account on the OtoSense Cloud, and all data (sensor data, insights, account information, etc.) is partitioned using the customer ID as the top-level partition key. Access to customer data is restricted to members of the customer account, and access authorization is enforced via Identity and Access Management services offered by premier cloud services providers.

User management

Role-based access and authorization

The first user for a customer account on the OtoSense Cloud is invited by ADI as an admin for their account. Upon accepting the invitation, the new admin user may create additional users with appropriate authorizations to manage the SMS devices and data for the account. News users receive an email with an invitation to activate their account and create a new password.

Device-to-cloud security

Mutually-authenticated TLS enforced

Sessions between the SMS Device and the OtoSense Cloud are exclusively established via mutually-authenticated TLS. All data to or from the SMS Device is encrypted and transmitted via the MQTT-over-TLS protocol. This includes sensor data, commands sent from the OtoSense Cloud to the SMS Device, and over-the-air updates transmitted to deployed SMS devices. 

Login portal security

Industry trusted login service providers

User account creation, management, and username/password login security (including password reset functionality) directly leverages trusted user management and authentication services from premier identity and login service providers, which ensures safe and secure user login from both the mobile application and web dashboard.

Device-to-cloud security

Mutually-authenticated TLS enforced

Sessions between the SMS Device and the OtoSense Cloud are exclusively established via mutually-authenticated TLS. All data to or from the SMS Device is encrypted and transmitted via the MQTT-over-TLS protocol. This includes sensor data, commands sent from the OtoSense Cloud to the SMS Device, and over-the-air updates transmitted to deployed SMS devices. 

Login portal security

Industry trusted login service providers

User account creation, management, and username/password login security (including password reset functionality) directly leverages trusted user management and authentication services from premier identity and login service providers, which ensures safe and secure user login from both the mobile application and web dashboard.

SMS device identity

Cryptographic identity for each SMS device

Each SMS device is provisioned from the factory with a cryptographic private key and corresponding PKI certificate unique to each device which serves as the identity for that device for all connections to the OtoSense Cloud. This unique key pair ensures that only device connections to the OtoSense cloud from authentic, ADI-manufactured SMS devices are allowed.

Client device session security

Enforced session encryption and authentication

All web and network traffic between the user's device and the OtoSense Cloud is protected by TLS encryption, and all user interaction with the OtoSense Cloud requires the presence of a valid ID token along with every request, which can only be acquired after successful authentication via username and password login.

OTA update validation

Digital signature validation for OTA updates

SMS devices are equipped from the factory with an ADI code verification PKI certificate, which is used by each SMS device to cryptographically validate a digital signature provided along with all software updates received over-the-air from the OtoSense Cloud. Unsigned OTA update payloads are strictly rejected.

Industries

Improve performance,
no matter the environment

Pharmaceutical

Pharmaceutical manufacturing requires on tightly controlled conditions to deliver critical medical and healthcare supplies to customers. Eliminating unplanned stops and reducing downtimes minimize material and product loss, while maintaining production throughputs so critical supplies can be delivered on time and within specification to your customers.

Eliminating unplanned stops and reducing downtimes minimize material and product loss, while maintaining production throughputs so critical supplies can be delivered on time and within specification to your customers.

Food & beverage

Food and beverage production relies on continuous operation to meet population demands while minimizing variation. Line stops directly impact food quality, yields and potentially contribute to contamination. Monitoring cooling systems and other critical equipment minimizes potential downtime and ensures high levels of operation to meet the growing demand across the globe.

Line stops directly impact food quality, yields and potentially contribute to contamination. Monitoring cooling systems and other critical equipment minimizes potential downtime and ensures high levels of operation.

Energy

Beyond the main generators at energy plants is a supporting network of equally critical motors and equipment. Downtime in this equipment will impact on the overall power output of the plant. By continuously monitoring this equipment, manual maintenance routines can be removed, costs reduced and efficiency process improved.

Beyond the main generators at energy plants is a supporting network of equally critical motors and equipment. Downtime in this equipment will impact on the overall power output of the plant.

Water utilities

Droughts occur more and more frequently in today's world. As a consequence, water resources need to be managed more effectively. The Smart Motor Sensor provides a cost efficient and reliable solution for your remote pump operation. For example, it allows a better use of aquifers. It can also benefit other activities such as the proliferation of wastewater treatment, water purification, desalination and transfers between basins.

Droughts occur more and more frequently. As a consequence, water resources need to be managed more effectively. The Smart Motor Sensor provides a cost efficient and reliable solution for your remote pump operation.

Paper

In the paper industry, the proper functioning of paper machine motors is vital. The failure of one of the motor that drive the different rollers or pumps of the process will be enough to cause a production stop and loss of material. ADI OtoSense SMS facilitates monitoring of these motors along with others on critical machines that drive pulpers, ensuring production uptime.

The failure of one of the motor that drive the different rollers or pumps of the process will be enough to cause a production stop. ADI OtoSense SMS facilitates monitoring of these motors along with others on critical machines that drive pulpers.

Technical information

Specifications and requirements

  • The Smart Motor Sensor (SMS) works with:

    • 3-phase squirrel cage induction motor.
    • Standard low voltage IEC and NEMA motors.
    • Frames up to 450 (IEC 60034) or 500 (NEMA MG1) whose power range varies from 0.37 kW to 500 kW or from 0.5 hp to 700 hp.
    • Motors driven by any type of device (directly on line (DOL)), by variable frequency drive (VFD), soft starter, and star-delta.
  • Physical characteristics

    Weight
    0.5 kg
    Case material
    ABS
    Mounting
    Cooling fins
    Battery type
    4 × replaceable AA lithium batteries

    Vibration measurement

    Amplitude range
    ±40 g
    Frequency range
    1 Hz to 3.1 kHz
    Data format
    Waveform, FFT, rms
    2-axis vibration
    Axial and radial

    Wireless communication

    Network standard
    Wi-Fi b/g/n
    Radio standard
    IEEE 802.11 b/g/n
    Frequency
    2.4 GHz
    Range (nominal)
    >50 m

    Certifications and standards

    CE
    IP Class IP55
  • Network

    Network
    Dedicated 2.4GHz network (5GHz networks not supported)
    Security
    WEP, WPA, or WPA2
    Signal strength
    Greater than -60dB
    Ports
    Port 8883 and HTTPS port (port 443) must be open.

    Environment

    Operation
    –40 ̊C to +60 ̊C
    Storage
    50 ̊C maximum to avoid energy leakage from lithium batteries

    App

    iPhone
    iOS 13 or later
    iPad
    iPadOS 13 or later
    Android phone or tablet
    Android 6.0 (Marshmallow) or later

Get started with our trial kit today

Start a dialogue to unlock the power of predictive maintenance for electric motors.

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