The Challenge
The project was funded through the Innovative Business Groups Support Program (AEI) of the Spanish Ministry of Industry, Trade and Tourism and developed collaboratively by BARBARA, EIA21, EQUIPEL, and SOAR, under the coordination of the Basque Energy Cluster and INNOVASTURIAS.
Industrial companies increasingly require advanced solutions that improve electric motor performance, reduce unplanned shutdowns, and maximize the efficiency and availability of critical assets.
Within this context, the main challenge was to develop an Intelligent Motor Control Center (MCC) capable of collecting, processing, and analyzing operational data in real time to optimize industrial asset management.
Key technical challenges included:
- Integrating IoT technologies into industrial motor control centers.
- Developing a digital twin for AC electric motors.
- Continuous monitoring of equipment operating conditions.
- Predicting potential failures through advanced data analytics.
- Estimating the remaining useful life of critical components.
- Implementing predictive and preventive maintenance strategies.
- Improving operational efficiency and plant availability.
The Solution
EIA21 contributed to the development of an innovative solution based on industrial digitalization, IoT technologies, and digital twins, transforming a conventional Motor Control Center into an intelligent platform for advanced electric motor management.
The main activities included:
- Design and development of the system’s functional architecture.
- Integration of sensors and IoT technologies for operational data acquisition.
- Development of digital models to virtually represent motor behavior.
- Implementation of diagnostic and analytical algorithms.
- Development of predictive maintenance and asset degradation assessment functionalities..
- Validation of the solution in real industrial environments.
Results
- Development of an intelligent MCC with advanced monitoring and analytics capabilities.
- Implementation of a digital twin for AC electric motors.
- Enhanced predictive and preventive maintenance capabilities.
- Improved asset lifecycle management.
- Increased knowledge and practical application of IoT technologies in industrial electrical infrastructure..
- Contribution to the advancement of Industry 4.0 and industrial digitalization within the energy and manufacturing sectors..
