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Smart Sensor: permanent online monitor

A new era of remote condition monitoring for low voltage motors has arrived.  ABB Ability™ Smart Sensor picks up data on vibration, temperature and other key parameters and uses it to reduce motor downtime by up to 70%, extend lifetime by as much as 30% and lower energy use by up to 10%.


Condition monitoring for a plant’s entire LV motor fleet

Up to now it has been too expensive to use permanently installed condition monitoring with LV motors. As a result most LV motrs are simply run until they fail.

ABB,s new solution enables almost all LV motors to be remotely monitored. Condition monitoring means that maintenance can be planned in advanced, which reduces downtime and saves money. By producing status data for a large number of motors, the solution also paves the way for plant-wide optimisation of operations and energy consumption. 


Condition monitoring solution for low voltage motors

Motors that let you know when its time for a service


New condition monitoring solution connects low voltage (LV)motors with the twenty-first century. It monitors and provides vital motor performance intelligence that helps improve uptime, extend motor lifetimes, and increase machine performance and productivity. It connects motors with the internet of things, services and people (loTSP). 

Smart sensors fitted to motors

Selected ranges of ABB LV motros will be factory fitted with smart sensor units as an option. The sensors can also be retrofitted on installed motors.

The external sensor monitors signals from the motor. The data is transferred using the units built-in Bluetooth via either the user’s smartphone or an ABB gateway solution, over the internet, to a secure cloud-based server.

The server analyses the data and produces meaningful information, which it sends directly to the user’sb smartphone or to a dedicated customer portal.

The intuitive interface includes a simple “traffic light” display to give a quick overview of the plant’s motors. 

the system detects a problem that needs attention, it send an alert to the user’s smartphone. From the portal the user can access trend data as well as data on run time and loads, enabling optimum maintenance planning. 


Monitoring of key parameters

Key parameters that are regularly and accurately monitored are:

Health related information

  • Rotor health
  • Temperature
  • Air gap eccentricity
  • Cooling condition
  • Bearing condition
  • Overall vibration

Operating information

  • Energy consumption (within 10%)
  • Loading (Power)
  • Operating hours

Main benefits

  • Increased motor uptime
  • Longer motor lifetime
  • Improved motor performance and productivity 


Simple traffic light display gives a quick overview of motor status. By drilling down the user can identify what triggered a yellow or red signial, e.g bearing related data has exceeded present limit. 

By providing meaningful information on motor condition and performance, the service will enable users to plan their maintenance according to actual needs rather than on the basis of time intervals or operating hours alone. This will reduce maintenance cost and enable the plant to cut or even eliminate unplanned stops.

There are also opportunities to optimise motors’ energy consumption – by combining data on the energy consumption levels of individual motors with plant operating information, it will be possible to formulate better loading strategies aimed at cutting energy costs.

Taken together , condition and performance data could provide a useful basis for reducing the overall cost of motor ownership in process plants by cutting both the motors cost of running as well as the risk and cost of not running. 

Condition monitoring solutions for LV motors. The smart sensor transmits data either via a smartphone or gateway solution to a secure server. 

Please contact us if you would like to book a demonstration of a smart device, or disscus your requirements.