Manufacturing · Utilities · Commercial · Industrial

Predict motor failures weeks before they happen.

Seven fault categories. Continuous monitoring. One health score.

MotorGuard AI combines vibration FFT analysis and motor current signature analysis to detect bearing faults, rotor imbalance, misalignment, and thermal issues weeks before failure. Health score 0–100 updated every 60 seconds.

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Photo: Industrial Motor / VFD Panel / Vibration Sensor
Product photo goes here
The Problem

Every motor failure starts as a signal. Most systems never see it.

Bearing failures, rotor imbalance, misalignment, cavitation — every fault produces a distinct signature in vibration and current data weeks before visible failure. Conventional motor protection trips the breaker after the damage is done. MotorGuard predicts the fault before it becomes a failure.

Health score 0–100. Time-to-failure estimate. Specific fault identification. Maintenance work order generated automatically. Try it in the live interactive demo.

Bearing fault detection (BPFO, BPFI, BSF, FTF)
FFT analysis identifies bearing fault frequencies at their characteristic defect frequencies — weeks before audible noise or vibration is noticeable.
Motor Current Signature Analysis (MCSA)
Current waveform analysis detects rotor bar defects, air gap eccentricity, and load variations without physical access to the motor.
Baseline fingerprinting
Learns your specific motor's healthy signature. Any deviation — regardless of fault type — triggers investigation. Works even for uncommon fault modes.
What MotorGuard Detects

Seven fault categories. Continuous monitoring.

Bearing Wear
BPFO, BPFI, BSF, FTF frequencies via FFT. Early detection weeks before audible symptoms.
Rotor Imbalance
1x vibration amplitude trending. Detects mass imbalance from buildup, erosion, or breakage.
Misalignment
1x and 2x radial + axial vibration patterns. Angular and parallel misalignment differentiated.
Cavitation
High-frequency vibration bursts. Detects pump cavitation before impeller damage occurs.
Rotor Bar Defects
MCSA sidebands around line frequency. Detects broken or cracked rotor bars.
Thermal Trending
Winding temperature trending. Predicts insulation breakdown before catastrophic failure.
Resonance Detection
Operating frequency proximity to natural frequency. Prevents resonance-induced failures.
Technical Specs

Industrial grade. Non-invasive installation.

Edge HardwareNVIDIA Jetson Orin NX in NEMA 4 enclosure
VibrationADXL357 3-axis accelerometer · 2kHz+ sampling · DIN rail mount
CurrentSplit-core CT clamps (100A / 500A) · 3-phase monitoring
TemperatureDS18B20 winding temperature · Differential thermal
AI / MLPython FFT · Isolation Forest · LSTM trending · MCSA analysis
Health Score0–100 per motor · Updated every 60 seconds
DashboardWeb portal · Mobile alerts · Maintenance work order generation
IntegrationModbus RTU/TCP · MQTT to AWS · REST API
Motor TypesAC induction · DC motors · Pumps · Fans · Compressors · Conveyors
Power Range0.5 HP to 500+ HP
Live Demo Available

Try the interactive Edge AI motor protection simulator. Adjust mechanical load, ambient temperature, and voltage imbalance in real time. Watch the AI predict overcurrent before it trips the motor.

⚡ Launch Live Demo →
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Motor Installation Photo
Vibration sensor on motor housing or VFD panel

Ready to stop reacting to motor failures?

Start with your most critical motor. We instrument it, establish a baseline, and you have a health score within two weeks. Fixed-price pilot scope.

Schedule a Site Review → ⚡ Live Demo