Advanced Motor Monitoring and Diagnostic Function for Siemens Servo Motors and Drives

We have developed a robust and scalable function dedicated to real-time analysis of motors controlled via SINAMICS S120/210, V90, and G120x drives and servo systems. It extracts relevant data, interprets it logically, and automatically triggers actions based on the motor’s actual condition.

✅ Function Capabilities:

• Monitors real-time temperatures, current, torque, and rotational speed

• Dynamically calculates the mechanical power developed by the motor and compares it to the nominal value to determine utilization

• Generates a percentage motor load indicator (“Motor Utilization”), easily displayed on HMI

• Stores maximum values reached for torque, speed, current, and utilization

• Automatically filters unstable or incorrect values to avoid displaying or processing false data

• Triggers alarms when predefined limits are exceeded (e.g., overload)

📊 End Result:

• A clear, real-time view of motor status

• “Clean” and filtered data, ready for display or logging

• A local diagnostic system, integrable into any HMI

• Predictive control to prevent overload or failures

• Maximum values saved for audit, maintenance, or analysis

🧩 Key Benefits by Application:

DomainConcrete BenefitHigh-speed automated linesEarly detection of subtle mechanical issuesHMI / SCADA systemsClear, structured data without fluctuationsPredictive maintenanceSchedule downtime based on actual wearPerformance testingMaximum visibility of motor behavior

🔄 Integration:

• Compatible with all SINAMICS S120/210, V90, and G120x drives and can be applied to any motor configured in TIA Portal

• Easily extendable with SD card logging, OPC UA, graphical interface, or cloud analysis