Volt Electric Motors – Motor Health Monitoring System

Volt Electric Motors is a leading manufacturer with a broad customer base in Turkey. Although great importance is placed on quality on the production line, there was no clear data on how motors performed in the field or under which conditions they failed. This uncertainty affected both customer satisfaction and warranty processes. Volt approached us with the need for a system that could monitor how its motors operate in the field and detect potential failures in advance.

Our team developed low-cost sensor hardware that can be integrated into the motors and an analytics infrastructure to interpret the data coming from them.

Project scope included:

• Sensors measuring key physical parameters such as temperature, vibration, current and voltage were integrated into the motors
• These data were processed with Python-based analytics software to produce motor health scores
• A .NET-based interface provided customers and technical support teams with real-time monitoring, historical data and an alert system
• Automatic warnings and maintenance suggestions were developed for abnormal behaviors that could lead to failures

The main challenges we addressed with the project were:

• Lack of information about motor performance after sale
• Inadequate ability to take precautions before a failure occurs
• Technical support being reactive (intervening only after issues)

With the system we developed: • Motors became remotely and in real time monitorable • Early warning based on symptoms enabled proactive maintenance • Technical support teams now have information before going on-site • Communication with customers became data-driven—analysis replaced guesswork

After the system went live:

• Fault detection rates before failure increased significantly
• Post-sales intervention time decreased by 40%
• The number of damages outside warranty coverage decreased
• A noticeable increase in customer satisfaction was achieved
• Motor replacements due to failures dropped substantially