ABB has unveiled a transformative approach to modernising variable speed drives (VSDs) by turning them into predictive maintenance gateways for entire powertrains. Launched at ADIPEC 2025 in Abu Dhabi, the service embeds Samotics’ Electrical Signature Analysis (ESA) technology into legacy drives, offering real-time insights into asset conditions. This development stems from ABB’s strategic partnership with Samotics, initiated in 2022, to integrate ESA into high-power drives, thereby facilitating digital transformation across industrial assets, including those in challenging environments.
By embedding ESA technology directly in the drive, ABB enables advanced condition monitoring across powertrain components such as motors, pumps, and conveyors. The technology identifies operational changes, like bearing wear or gear misalignment, allowing for preemptive maintenance actions that prevent costly failures and downtime. Oswald Deuchar, Global Head of Modernization Program at ABB Motion Services, highlights that this innovation supports seamless ESA technology adoption, bolstered by ABB’s global support network.
Simon Jagers, Founder & co-CEO of Samotics, notes that ESA’s integration allows monitoring of assets in extreme conditions, paving the way for autonomous operations in future factories. The ESA-powered drives collect electrical data, which is analysed by Samotics and distributed through ABB’s network, providing actionable insights that enhance operational resilience and maximise uptime.
Initially, this ESA modernisation service targets ABB’s ACS600 and ACS800 low-voltage VSDs, which now include TÜV-certified cybersecurity measures. Part of ABB Ability™ Condition Monitoring, ESA complements ABB’s vibration analysis, ensuring comprehensive powertrain health insights. Deuchar concludes that embedding ESA transforms drives into intelligent sensors, enabling maintenance teams to preempt performance-impacting faults, thus supporting smarter, more efficient industrial operations.
