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<\/p>\nMotors play a central role in manufacturing. But motor failures can drag down productivity and drive up maintenance costs. To solve this problem, Daliworks developed SignalVax, an AI-based motor diagnostics service that analyzes motor conditions in real time and detects anomalies before they become failures. In this article, we look at how SignalVax transformed a customer’s equipment operations.<\/p>\n
SignalVax is a solution that analyzes a motor’s electrical signal data in real time to predict failures in advance and optimize maintenance efficiency. After collecting current, voltage, and power data, it uses AI to identify anomalies in motor equipment and perform early diagnostics.<\/p>\n
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SignalVax overview<\/p>\n
When a physical fault develops in a motor’s shaft, bearings, or mounting, its electrical signals change. SignalVax detects these changes to quickly identify electrical and mechanical defects. In particular, it uses machine learning and LSTM (Long Short-Term Memory) techniques to detect anomalies and provide predictive models. It has already proven its value in production at chemical, basic materials, and steel companies.<\/p>\n
\u2013\u00a0Diagnose equipment issues before failures occur<\/p>\n
\u2013\u00a0Longer equipment life and higher uptime<\/p>\n
\u2013\u00a0Lower energy costs and reduced maintenance spending<\/p>\n
Customer A is a KOSPI 200 company with multiple factories both in Korea and overseas. We ask for your understanding that, for security reasons, photos of the customer’s site cannot be used.<\/p>\n
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For security reasons, we are showing a photo of a different factory.<\/p>\n
Customer A operates large-scale manufacturing facilities where maintaining continuous processes is essential. Its main motor applications were as follows.<\/p>\n
\u2013 Descaling pumps (for scale removal)<\/p>\n
\u2013 Air compressors (pneumatic supply)<\/p>\n
\u2013 Gas exhaust systems (emission gas management)<\/p>\n
\u200bPreviously, the company kept spare motors on hand and swapped them in immediately whenever a failure occurred. But this approach carried a high risk of rising maintenance costs and unexpected production disruptions. The customer therefore began looking for a solution capable of early diagnostics.<\/p>\n
Customer A ran a PoC (Proof of Concept) across several motor monitoring solutions. After comparing a variety of sensors and diagnostic methods, including vibration and sound, SignalVax \u2014 built on AI analysis of current signals \u2014 was selected as the most effective option, for the following reasons.<\/p>\n
\u200b- Easier to install than conventional physical sensors, and deployable without additional hardware changes<\/p>\n
\u200b- Data-driven AI analysis improves anomaly detection and prediction accuracy<\/p>\n
\u200b- Current-signal diagnostics detect failures faster and more accurately than other existing sensors<\/p>\n
\u200bCustomer A was already running its own in-house IT systems to manage complex production and, for security, wanted an in-house deployment. SignalVax is offered primarily as a subscription, but to meet the customer’s requirements it was installed on-premise. It was also configured to integrate with the company’s own equipment operation system, so problems could be identified and addressed within the overall factory system.<\/p>\n
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Example SignalVax screen<\/p>\n
Since adopting SignalVax, Customer A has shifted from reactive maintenance to a framework of early diagnosis and preparedness. Specific outcomes include the following.<\/p>\n
\u2013 Applied to 107 motors at Plant 1 and 45 motors at Plant 2<\/p>\n
\u2013 Real-time alerts and preventive action when anomalies occur<\/p>\n
\u2013 Longer equipment life and greater operational stability through continuous monitoring<\/p>\n
\u2013 Plans being developed to expand to additional processes<\/p>\n
Daliworks’ SignalVax is an innovative solution that detects motor anomalies in advance through AI-based electrical signal analysis, raising the operational stability of manufacturing equipment. As Customer A’s case shows, building a PdM (Predictive Maintenance) framework delivers tangible benefits: higher equipment uptime, lower energy costs, and reduced maintenance spending.<\/p>\n
\u200bWith equipment continuity and reliability so critical in manufacturing, AI-based motor diagnostics look set to become an essential tool for more and more companies. We look forward to seeing how SignalVax will be used across an even wider range of industries.<\/p>\n
\u2705 Related content worth reading<\/strong><\/p>\n What Is Motor Diagnostics? The Concept and Why It Matters<\/a><\/p>\n<\/blockquote>\n\n