Electric Motor Health Monitoring
Electric motors are the heartbeat of industrial production. Fizix detects mechanical and electrical faults weeks before failure — with a magnetic-flux sensor that sees what vibration alone cannot.
Motors fail two ways. Fizix watches both.
A single Fizix smart multi-sensor device captures 3-axis vibration, acoustic emission, magnetic flux and temperature — computing dozens of indices on-device. Vibration and acoustic cover the mechanical side; the magnetic-flux channel covers the electrical side that vibration-only tools miss.
Everything streams to the AI-powered Mate platform, where a digital twin and fault library classify what's wrong, how severe it is, and what to do next.
The Most Common Source of Industrial Downtime
Electric motors power virtually every process in industry — pumps, fans, conveyors, compressors and mills. They are the most common rotating machine, and also one of the most frequent causes of unplanned downtime.
Motor failures usually begin as bearing degradation, rotor eccentricity, winding faults or misalignment — all detectable weeks in advance with the right sensing. Manual route-based inspection simply cannot catch electrical faults early enough.
Fizix combines vibration, acoustic emission, magnetic flux and temperature in a single device. The magnetic-flux channel is purpose-built for electric motors, exposing broken rotor bars, winding shorts and air-gap eccentricity that vibration analysis misses entirely.
WHERE MOTORS ARE CRITICAL
What Fizix Detects on Your Motors?
Each fault leaves a distinct signature across vibration, acoustic emission, magnetic flux or temperature. Fizix catches them weeks before failure — and tells you which smart multi-sensor device saw it.
Unbalance
Rotor mass imbalance drives 1x rotational vibration that overloads bearings and wastes energy.
Bearing Failures
Inner-ring, outer-ring, ball and cage defects caught at the earliest stage via envelope & acoustic signatures.
Shaft Misalignment
Angular and parallel misalignment between motor and driven load — a leading cause of premature seal and coupling wear.
Broken Rotor Bars
Cracked or broken rotor bars produce characteristic sidebands in the magnetic-flux spectrum — invisible to vibration.
Stator Winding Shorts
Inter-turn winding faults detected early through their magnetic-flux signature, before thermal runaway.
Rotor Eccentricity
Static and dynamic air-gap irregularities that raise vibration, heat and losses — resolved by flux analysis.
Mechanical Looseness
Loose mountings, end-bells or couplings that amplify vibration and accelerate every other fault.
Overheating
Cooling loss, overload or electrical fault verified through on-device temperature trending.
The Magnetic-Flux Advantage
Half of all motor failures are electrical — broken rotor bars, winding shorts, air-gap eccentricity. Vibration analysis is effectively blind to them. Fizix embeds a dedicated magnetic-flux sensor that reads the motor's electromagnetic signature (MCSA) and exposes electrical faults weeks before any thermal or vibration symptom appears.
✕ Vibration only
A broken rotor bar produces almost no vibration change until it cracks a second bar — by then the rotor is failing.
✓ Vibration + Flux
The same fault appears as clear pole-pass sidebands around supply frequency in the flux spectrum — an unambiguous early warning.
One Platform, Value For Every Role
From the boardroom to the shop floor, motor monitoring delivers something different — and useful — to everyone who keeps production running.
Plant & Reliability Leaders
Turn unplanned motor failures into planned, budgeted work
A clear ROI and payback you can take to finance and the board
Fleet-wide visibility across every motor — one plant or many
Lower safety exposure and fewer emergency interventions
Predictable spend, less capital tied up in spares
Operations & Production Teams
Keep the line running — no process interruption to install
A simple health score per motor, readable without expertise
Alerts before a trip, so you shut down on your terms
Know which asset actually needs attention first
Web & mobile dashboards for the whole shift team
Maintenance & Reliability Engineers
Pinpoint the fault type and location on each motor
Plan repairs into routine stops, not emergencies
Order the right spare at the right time — no over-stocking
Guided diagnostics without deep vibration expertise
Remote checks — fewer trips into hot, hazardous zones
Reactive Maintenance vs Fizix
Most plants still run motors on calendar schedules and walk-around checks. Here's what changes when your motors talk to you.
See What Fizix Could Save You
Move the sliders to match your motor fleet. This is an indicative estimate — book a free consultation for a validated, site-specific business case.
Defaults reflect a typical motor-heavy plant. Adjust to your own figures.
Based on Fizix reference outcomes: up to 50% less downtime, 35% lower maintenance cost, ~134 kg CO₂/day per 200 kWh motor. Indicative only.
From Smart Multi-Sensor Device to Insight
An end-to-end solution connecting your motors to actionable intelligence in real time — installed in minutes, with no process interruption.
Mount in <15 min
The smart multi-sensor device attaches to the motor's drive-end or non-drive-end bearing housing — no rewiring, no stop.
Sense electrical + mechanical
Vibration, acoustic, flux and temperature captured 24/7 and processed at the edge.
Flux + digital twin
Mate separates electrical faults (rotor bars, windings) from mechanical ones automatically.
Act on a clear score
Instant alerts with a health score tell you whether it's a bearing, alignment or winding issue.
How Fizix Protects Your Motors
Smart multi-sensor devices in the field capture four signals — analyzed on the cloud-based Fizix Mate platform.
Catch Electrical Faults Early
Magnetic-flux analysis reveals broken rotor bars, winding shorts and eccentricity that vibration-only systems never see — the difference between a planned repair and a burned-out motor.
Bearing & Alignment Protection
Envelope and acoustic analysis flag bearing and misalignment defects weeks ahead, so you replace on your schedule, not the motor's.
Lower Energy & CO₂
Imbalance, eccentricity and misalignment quietly inflate power draw. Fizix exposes inefficient operation — up to 134 kg CO₂/day saved per 200 kWh motor.
Avoid Replacement Costs
In one polyester-production case, early detection avoided a full motor replacement worth ~$140K.
ATEX-Ready Coverage
ATEX-certified options let you monitor motors in classified areas without hot-work permits or safety compromise.
One Dashboard, Every Motor
Every motor across a line, plant or fleet visible from a single Mate dashboard — web and mobile.
What We Detect & Measure?
Fizix combines multiple measurement technologies to give complete motor health visibility.
Vibration Analysis
Time waveform, spectrum, envelope and waterfall up to 26.6 kHz.
Acoustic Emission
Early bearing and lubrication faults up to 80 kHz.
Magnetic Flux
Rotor bars, winding shorts and eccentricity up to 32 kHz.
Temperature
Thermal fault verification and overheating detection.
RPM Estimation
Speed tracking from vibration & flux for load-normalized trending.
Statistical Indices
RMS, Crest Factor, Kurtosis, Skewness, Peak — computed on-device.
Fizix Smart Multi-Sensor Devices for Motor Monitoring
Choose the right smart multi-sensor device for each motor's criticality and environment.
Best for Critical Assets
Wired power for 24/7 continuous streaming. For high-criticality assets where any downtime is unacceptable.
Best for Important Assets
Battery-powered with up to 5-year life. ATEX-certified for hazardous areas. Wireless and quick to install.
Best for Balance-of-Plant
Bluetooth, compact and economical. Ideal for monitoring many assets across a facility cost-effectively.
Impact on Motor Reliability
Typical outcomes reported across Fizix deployments. Actual results vary by asset condition and baseline.
Figures reflect "up to" improvements observed across Fizix installations and the 200 kWh reference calculation for CO₂. Company-wide figures (150M+ monitoring hours, 40,000+ connected machines, 18+ sectors) are as of 2025. Asset-specific results should be validated during a pilot.
Request a Free Expert Consultation
Tell us about your motors and what you want to protect. A Fizix specialist will get back to you within one business day to discuss your goals and outline a tailored path forward — with no obligation.
Free 1:1 consultation with a reliability expert
Assessment of your critical motors
Tailored sensor & Mate platform recommendation
Optional pilot to prove ROI before scaling
Monitor Your Motors Before They Fail
Add a Fizix device to any critical motor and start receiving mechanical and electrical health insight within minutes.
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