SUCCESS STORY – Detection of a Critical Electrical Fault Using EI-Analytic™ & PHANTOM®

In an automotive manufacturing plant based in Morocco, a critical production asset began to exhibit abnormal vibration behavior.

Key Context Elements:

• Client: International automotive manufacturer

• Location: Morocco

• Machine Type : 1000 T stamping machine

• Initial Issue: Unusual noise and suspected abnormal vibration

• Partner Involved: CBM Partners

• Intervention Date: May 16, 2025

• Project Lead: Abdelilah SERDI, CBM Consultant

• Objective: Identify the source of the anomaly through structured vibration monitoring

  The client aimed to detect potential faults early, without interrupting production or performing intrusive maintenance.

Technology Used

• 12 PHANTOM® wireless sensors – ERBESSD INSTRUMENTS®
• EI-Analytic™ cloud-based monitoring platform
• Monitoring based on continuous data acquisition.
• Alarm system configured according to machine-specific thresholds

Symptom Detected After 12 Hours of Data Acquisition

Twelve hours after activating the PHANTOM® sensors, the EI-Analytic™ platform triggered an automatic alarm indicating abnormal vibration behavior.

FFT Spectrum Characteristics:

• Clear, repeated peaks at 100 Hz, 200 Hz, and 300 Hz
• Frequencies perfectly aligned with multiples of the power supply frequency (50 Hz)
• No typical mechanical components present (e.g., imbalance, misalignment, gear mesh)

Diagnosis

Likely fault origin:

1. Phase imbalance
2. Insulation defect
3. PWM switching noise from the motor drive

✔ Detection was only possible through continuous vibration monitoring

Observed Vibration Spectrum

Recommended Actions (Pending Execution)

1. Perform motor current analysis (imbalances and harmonics)
2. Inspect electrical connections and grounding
3. Verify motor drive settings
4. Conduct insulation resistance testing

Estimated Economic Impact

Thanks to early analysis:

• The fault was identified before failure
• A targeted intervention is being prepared
• An estimated €300,000 motor replacement cost was avoided

Client Benefits

• Continuous monitoring without halting operations
• Early detection of an invisible electrical fault
• Prevention of an unplanned shutdown
• €300,000 cost avoidance
• Full validation of predictive maintenance strategy

Project Testimonial

“Thanks to the power of the EI-Analytic™ platform and PHANTOM® sensors from ERBESSD INSTRUMENTS®, we were able to trigger a reliable alert in less than 12 hours.

Further measurements later revealed signs of lubrication deficiency and a bearing defect, reinforcing the severity and confirming a mechanical degradation.

This is a concrete demonstration of the value predictive maintenance brings in a high-stakes industrial environment.”

— Abdelilah SERDI, CBM Consultant – CBM Partners