A Leading Manufacturing Company


A prominent manufacturing company faced operational challenges stemming from unexpected faults in its three-phase squirrel-cage induction motors. The absence of an early fault detection system led to increased maintenance costs and disrupted production, adversely affecting overall operational efficiency. 


Recognizing the need for a proactive approach, we proposed an advanced Predictive Maintenance System leveraging Artificial Intelligence (AI) and Machine Learning (ML) for early detection of induction motor faults. The core of our solution focused on Motor Current Signature Analysis (MCSA) using sophisticated AI algorithms. 

Solution Features

  1. Motor Current Signature Analysis (MCSA): 
    • Utilized AI/ML algorithms to analyze phase currents for precise fault detection. 
    • Comprehensive fault coverage, including bearing faults, air-gap eccentricity, short winding faults, and load imbalances. 
  2. Data Acquisition Hardware: 
    • Developed robust and easy-to-configure hardware units capable of operating in harsh industrial environments.
    • Battery-powered devices with Wi-Fi communication for seamless data transmission.
  3. Web Application for Data Management: 
    • Designed an intuitive web application for efficient data preprocessing and management of data acquisition hardware units.
    • Applied advanced analytics to establish relationships between motor faults and dynamic operating conditions.
  4. Mobile Application: 
    • User-centric mobile application for initiating the fault detection process. 
    • Real-time visualization of fault analysis results for quick decision-making. 
  5. Graphical Representation: 
    • Advanced graphical representations of parameters based on fault detection algorithms. 
    • Intuitive visualization aids in the easy interpretation of motor health. 

Solution Benefits

  1. Early Fault Detection: 
    • Proactively identifies faults in induction motors at an early stage, minimizing downtime and production losses. 
  2. Cost Savings: 
    • Reduces overall maintenance costs by addressing issues before they escalate into major faults. 
  3. Operational Efficiency: 
    • Optimizes the production line by ensuring the reliability and continuous operation of induction motors. 
  4. User Empowerment: 
    • Empower users with a mobile application for on-the-go monitoring and decision-making. 
  5. Customizable Alerts: 
    • Tailored alerts for specific fault types, enabling targeted and timely intervention. 
  6. Data-Driven Insights: 
    • Provides actionable insights derived from historical data, aiding in long-term maintenance planning. 


Machine Learning Frameworks: TensorFlow, Scikit-Learn
Web Application: Flask (Python), HTML, CSS, JavaScript
Data Processing: Pandas, NumPy
Database: MongoDB
Hardware Integration: IoT protocols (Wi-Fi communication)
Mobile Application Development: React Native


About Emorphis

Emorphis Technologies is a world-class software development and solutions company that truly believes in “Innovation in motion”. Delivery innovation on the go at an accelerated pace has been our success mantra to date. Over the years we have provided value to our clients in the field of enterprise mobility, cloud, IoT, backend development, Big Data Analytics, and Blockchain.

We serve industries ranging from unicorns, and startups to large multinationals in the healthcare, telecommunications, fintech, retail, and publishing industry. Our go-to-market software products – iStatement, iPublisher, and iBuggy have proved our metal with positive beneficial customer testimonials. We help our clients with successful product development, consulting services, and testing (manual & automated).

We have profound experience & expertise in various technologies like .Net, J2EE, PHP, iOS, Android, and Cloud Computing viz. Amazon Web services (AWS), Software QA & testing (Manual & Automation). Our designed products are cloud-ready and can be readily deployed on AWS/Azure cloud infrastructure.

Our pivot on engineering innovation and R&D helps quicken time-to-market, ensuring high quality at economies of scale, delivering cult competency for the global marketplace. We ensure that your ideas, concepts, and requirements are backed by brilliant execution at our end. Having said that we extend end-to-end ownership of product/application design, development, and deployment.

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+1 408 409 2024

+91 731 408 9351

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