Know Your Motors Are Failing Before Your Plant Does
SignaTE continuously monitors industrial electric motors using Electrical Signature Analysis, edge computing and AI, detecting rotor faults, bearing degradation and winding failures before they cause unplanned downtime.
For plant directors: know the financial exposure of every critical motor before it becomes an emergency. For reliability engineers: see the fault, its trajectory and the recommended maintenance window.
Four Ways Industrial Motor Maintenance Leaves Plants Exposed
Most industrial plants are running with significant gaps in their motor health visibility. Each of the four dominant maintenance approaches has a structural weakness that only becomes visible when a motor fails.
Reactive and Breakdown Maintenance
Plants that fix motors after they fail face unplanned line stoppages, emergency logistics and rush repairs. For plant directors, every unexpected failure is both an operational crisis and an unbudgeted cost event. For reliability engineers, it means being permanently reactive rather than in control.
Calendar-Based Preventive Maintenance Blind Spots
Fixed service dates create two distinct problems. Healthy motors are serviced unnecessarily, consuming budget. Meanwhile, motors that begin degrading mid-interval are missed entirely. The gap between service dates is a 90-day window during which a deteriorating motor can progress from early fault to failure.
Vibration Monitoring Cannot Reach Every Motor
Vibration sensors detect mechanical faults only after physical development has begun, reading the consequence rather than the cause. They cannot practically be deployed on submersible motors, motors in hazardous-area classifications or hard-to-reach assets. Dust, heat and classified environments prevent coverage of every critical motor.
DCS Alarms That Fire Too Late
Control systems alarm when a parameter crosses a threshold. By the time a DCS alarm fires, the fault condition has already developed. There is no advance maintenance window, only confirmation that a problem has arrived. Threshold alarms and predictive intelligence are not the same thing.
The SignaTE Motor Intelligence Platform
SignaTE is a continuous condition monitoring and motor intelligence platform built on Electrical Signature Analysis (ESA) and Motor Current Signature Analysis (MCSA), combined with edge computing and AI. It monitors every connected motor around the clock, delivering real-time health scores, fault alerts and degradation curves to a single fleet-scale dashboard.
The hardware is a CT clamp that connects at the motor control panel, outside the switchgear, with no disassembly and no sensors mounted on the motor body. Because the measurement is taken from the electrical supply, SignaTE can monitor motors that vibration-based monitoring cannot physically reach: submersible pumps, motors in ATEX hazardous-area zones and remote or hard-to-access assets.
This is what makes SignaTE distinct: it reads the electrical cause of a fault rather than the physical symptom that develops later. An AI baseline is built for each individual motor over 7 days of real production, accounting for load profile, VFD harmonics and ambient conditions. The first full health report is delivered within 7 days of deployment.
From Installation to First Health Report in 7 Days
SignaTE is designed for live industrial environments. Every step in the deployment sequence is built around the operational constraints of a running plant.
CT Clamp Installation at the Panel (Under 2 Hours)
A SignaTE field engineer installs the CT clamp at the motor control panel, outside the switchgear, with no disassembly of the motor or the switchgear itself. Up to 5 motors are connected in under 2 hours. No plant shutdown is required, no hot work permit is needed and no IT team involvement is necessary. The motor continues running throughout.
Edge Device Connects Automatically via 4G
The SignaTE edge device auto-connects via its embedded 4G SIM. No site network integration, no firewall configuration, no IT ticket. Within hours of deployment, the motors appear on the dashboard and health data begins streaming. The dashboard auto-refreshes every 10 seconds.
Per-Motor AI Baseline Built Over 7 Days
Over the first 7 days of real production, SignaTE builds an individual AI baseline for each connected motor, accounting for load profile, VFD harmonics and ambient operating conditions. Operating states are segmented so that a healthy motor running under transient load does not trigger a steady-state alert. The baseline re-anchors automatically after a confirmed maintenance event.
First Health Report Delivered Within 7 Days
Within 7 days of deployment, the first full motor health report is delivered, covering health scores per motor, any faults detected, the degradation trajectory for each fault and the recommended maintenance window. From this point, the platform monitors continuously and alerts via mobile app and email when fault type, severity trend or recommended action changes.
Detecting Faults at the Electrical Source, Not the Mechanical Symptom
SignaTE uses ESA to read the electrical fault signature carried in the motor's current waveform. Because it reads the electrical cause of a fault rather than the physical consequence, it identifies problems at inception, before any mechanical symptom has developed to the point where vibration monitoring would detect it.
Rotor Faults
Rotor bar integrity degradation is detectable in the current waveform long before any mechanical vibration or audible symptom emerges. SignaTE detects this signature and tracks its progression on the health score curve.
Bearing Degradation
ESA captures bearing-related fault signatures in the current spectrum, providing an independent detection path that does not depend on physical access to the motor body, particularly significant for submersible and hazardous-area motors.
Winding Failures
Insulation degradation and turn-to-turn faults produce characteristic changes in the motor's electrical behaviour. Early detection gives maintenance teams the opportunity to plan a controlled rewind or replacement rather than responding to an in-service breakdown.
0 to 100 Health Score
Rather than a binary alarm, every motor receives a degradation curve reflecting fault severity, rate of decline and criticality weighting. Plan intervention at the right moment, not after the fact.
Why Engineering Teams and Plant Directors Choose SignaTE
SignaTE is designed to close the coverage and detection gaps that existing monitoring programmes leave open. Each differentiator addresses a specific limitation of conventional approaches.
Monitors From the Panel, Not the Motor
The CT clamp connects at the motor control panel outside the switchgear. No sensors are mounted on the motor body, which means SignaTE can monitor submersible motors, motors in remote locations and motors in ATEX hazardous-area zones that vibration monitoring cannot practically cover.
Detects Faults Before Vibration Symptoms Appear
ESA reads the electrical cause of a fault. Vibration monitoring reads the physical consequence after it has already developed. By detecting faults at the electrical signature stage, SignaTE gives maintenance teams advance notice and a planned maintenance window rather than a reactive emergency.
Per-Motor AI Baseline With Load and VFD Awareness
Every connected motor receives its own baseline, built over 7 days of real production on that specific asset. The baseline accounts for load profile, VFD harmonics and ambient conditions, preventing transient operating states from generating false alerts on healthy motors.
Zero-Shutdown Deployment
Installation across 5 motors takes under 2 hours on a live plant. No shutdown, no hot work permit, no IT team. The edge device connects via embedded 4G SIM and appears on the dashboard within hours. Plants can deploy SignaTE without scheduling a production stop.
Live in 7 Days
Health scores update in real time from Day 1 of deployment. The first full motor health report, covering health scores, detected faults, degradation curves and recommended maintenance windows, is delivered within 7 days. Time-to-value is measured in days, not months.
Fleet-Scale Dashboard Across All Sites
Every monitored motor across every plant site appears in a single dashboard. Engineers can filter by health score, fault type, physical location and asset criticality. The dashboard auto-refreshes every 10 seconds, so the view is always current.
Integration With DCS, SCADA, PI System, SAP PM and Maximo
SignaTE connects to existing plant systems via OPC-UA, Modbus TCP and REST/Webhooks. Motor health data flows into the systems reliability engineers and maintenance planners already use. SAP PM and Maximo integration means fault alerts can directly inform work order creation.
Complements Existing Vibration Programmes
ESA and vibration monitoring detect different things at different points in the fault timeline. Most plants that add SignaTE keep their vibration programme running. SignaTE fills the coverage gaps (submersible, hazardous-area, remote motors) and the detection timing gap, while vibration monitoring continues to serve what it covers well.
Built by Tata Elxsi
SignaTE is a product of Tata Elxsi, bringing industrial-grade engineering discipline to hardware, firmware and the AI platform. The hardware is rated IP66, operates from minus 10 to plus 60 degrees Celsius, is EMI-hardened and IEC 61000-4 certified. ATEX Zone 2 option available.
Platform and Hardware Capabilities
SignaTE is built for the operational and technical requirements of large industrial facilities. The platform, hardware and integration architecture are specified to meet the conditions and system demands of heavy industry.
Real-Time Dashboard Refreshing Every 10 Seconds
The fleet dashboard updates every 10 seconds, giving operations teams a current view of motor health across all monitored assets. Filter options include health score, fault type, physical location and asset criticality, so engineers can direct attention to the motors that need it most.
Hardware Rated for Industrial Environments
IP66 ingress protection rating. Temperature range: minus 10 to plus 60 degrees Celsius. EMI-hardened and IEC 61000-4 certified, designed to function reliably in motor control centres and industrial switchrooms. ATEX Zone 2 certified option available for hazardous-area deployments.
Plant System Integrations via OPC-UA, Modbus TCP and REST/Webhooks
SignaTE integrates with DCS, SCADA, PI System, SAP PM and Maximo. Motor health data and fault alerts can be surfaced directly within the systems maintenance planners already work in, and fault events can trigger work orders in SAP PM or Maximo without manual data transfer.
Mobile App and Email Alerts With Fault Detail
When a fault is detected or a health score changes materially, alerts are sent via mobile app and email. Each alert includes the fault type, severity trend and recommended maintenance window, giving the recipient the information needed to make a maintenance planning decision.
Monthly Automated Executive PDF Reports
Every month, SignaTE delivers an automated PDF health report to operations leadership, covering fleet health trend, faults detected during the period, maintenance actions recommended and an ROI summary. Plant directors and maintenance heads get a regular, structured view without requiring them to log into the dashboard.
Wireless Connectivity via Embedded 4G SIM
The edge device connects to the SignaTE platform via an embedded 4G SIM, with no dependency on the site's IT network, no firewall configuration and no IT team involvement. Data begins streaming to the dashboard within hours of deployment, maintained independently of plant network availability.
Industries Where Motor Health Is a Production-Critical Concern
Electric motors are central to continuous and batch production across heavy industry. In every sector below, unplanned motor failure carries direct production, safety and cost consequences.
Steel and Metals
Blast furnace blowers, rolling mill drives, cooling fans and pump motors operate under continuous heavy load. A failure in a critical drive motor can halt production across the entire line.
Oil and Gas
Pump motors, compressor drives and injection motors running in classified hazardous areas where manual vibration inspection is restricted. ESA-based monitoring from the panel provides coverage where sensor-on-motor approaches cannot safely operate.
Chemicals and Petrochemicals
Continuous process plants cannot absorb unplanned motor failures without significant production loss and potential safety risk. Reactor feed pumps, agitators and compressors must be monitored with enough advance notice to plan shutdowns.
Power and Energy
Boiler feed pumps, cooling water pumps and induced draft fans are critical to maintaining generation output. Degradation in any of these assets directly affects plant availability. Early fault detection supports both reliability and regulatory compliance.
Cement and Mining
Kiln drives, ball mill motors and crusher drives operate in dusty, high-temperature environments that make manual inspection difficult and vibration sensor reliability inconsistent. Panel-based monitoring provides continuous coverage regardless of ambient conditions.
Water and Wastewater
Submersible pump motors and remote pumping station motors are among the most difficult assets to monitor conventionally. ESA monitoring from the control panel covers these assets with no access to the motor body required.
Manufacturing
Production line motors, conveyor drives, HVAC plant and compressor motors contribute to overall equipment effectiveness. Unplanned failure in any of these assets disrupts schedules, delays orders and creates expediting costs. Predictive monitoring shifts maintenance from reactive to planned.
Pharma and Food
GMP environments and food-safe production areas have strict controls over maintenance activity. Planned maintenance windows are essential and emergency intervention during production is costly and potentially compliance-critical. Early fault detection gives maintenance teams advance notice to schedule work outside production runs.
What Avoided Failures and Better Maintenance Are Worth to Your Plant
Avoided Unplanned Downtime
When a motor fails unexpectedly, the cost is not just the repair: it is the production that stops, the batches that are lost, the orders that are delayed and the emergency logistics that follow. The magnitude of this cost per hour varies significantly by industry, plant size and the criticality of the specific motor in the process.
Avoided Repair and Replacement Costs
A motor caught at an early fault stage can often be repaired or rewound during a planned stop. The same motor, run to failure, may require emergency replacement with the associated procurement time, expediting costs and potential damage to connected equipment.
Energy Efficiency Gains
A motor operating with developing winding or rotor faults draws more current to produce the same mechanical output. Early detection and planned correction of these faults can recover energy consumption that the fault was wasting.
Calculate What It's Worth for Your Plant
Use the SignaTE ROI and Savings Calculator to enter your own operational numbers and see what these three categories of value are worth for your specific plant and motor fleet.
Calculate Your SavingsFree 72-Hour Motor Health Check: See What Your Critical Motors Are Telling You
The SignaTE Free 72-Hour Motor Health Check is a no-cost, no-disruption way to find out the actual health status of up to 5 of your most critical motors. There is no obligation and no plant shutdown involved at any point.
A SignaTE field engineer visits your site and installs the CT clamp hardware at the motor control panel for up to 5 motors. Installation across all 5 motors takes under 2 hours on a live plant, with no shutdown, no hot work permit and no IT team involvement. The motors continue running throughout.
Over 72 hours, the edge device collects continuous ESA data from all connected motors. Within 7 days of deployment, you receive a full motor health report covering the health score for each motor, any faults detected, the degradation trajectory for each fault and the recommended maintenance window.
Up to 5 critical motors monitored
Under 2 hours installation on live plant
No shutdown, no hot work permit, no IT team
Full health report delivered within 7 days
No cost. No commitment to full deployment
90-Day Pilot Programme: Validate at Scale Before Full Deployment
For organisations that want to assess SignaTE's performance across a larger set of motors and over a longer period before committing to a full deployment, the 90-Day Pilot Programme provides a structured evaluation path.
You select the motors you consider most critical to your operation. SignaTE connects to that set, collects continuous ESA data for 90 days and delivers regular health reports throughout the period. At the end of 90 days, the results show what faults were detected, at what stage they were caught and what the maintenance outcome would have been without early warning.
The pilot is designed to give reliability engineers and maintenance heads the technical evidence they need and to give plant directors and operations leaders the business case they need. Both audiences see the same 90 days of data, presented in the terms most relevant to their decisions.
Installation and Go-Live
CT clamp installed at the motor control panel across your selected critical motors. Edge device connects via 4G. Motors appear on the dashboard within hours.
First Health Report
AI baselines complete. First full motor health report delivered, covering health scores, any faults detected and degradation trajectories to date.
Continuous Monitoring and Regular Reports
Continuous ESA data collection. Regular health updates and alerts throughout the pilot period. Live access to the fleet dashboard for all monitored motors.
Pilot Results Review
Full pilot results reviewed with both engineering and business stakeholders. Faults detected, timing of detection, recommended maintenance outcomes and business case summary.
Built by Tata Elxsi
SignaTE is a product of Tata Elxsi, an engineering and technology services company with deep capability across industrial product development, embedded systems and AI-driven platforms.
The SignaTE hardware, firmware and AI platform reflect the product engineering discipline that Tata Elxsi brings to complex industrial environments. The hardware is rated IP66, operates across a temperature range of minus 10 to plus 60 degrees Celsius, is EMI-hardened and IEC 61000-4 certified. An ATEX Zone 2 certified option is available for motors operating in hazardous-area classifications.
The platform is designed to meet the reliability, security and integration demands of large industrial operations, not laboratory or light-commercial conditions. The combination of Tata Elxsi's engineering background and the specific requirements of heavy industrial motor monitoring shaped every element of SignaTE's design, from the CT clamp hardware to the fleet-scale dashboard and the AI baseline engine.
Built for the People Responsible for Industrial Motor Reliability
SignaTE addresses three distinct audiences, each with different priorities and different questions about motor health monitoring. The platform is designed to serve all three.
Operational Continuity and Financial Exposure
Your concern is operational continuity and the financial exposure that comes with unplanned downtime. Every critical motor that fails without warning is a production stoppage, an emergency response and an unbudgeted cost. SignaTE gives you a continuous view of the health of every critical motor on your plant, with fault alerts that arrive in advance of failure. The monthly executive PDF report gives you a structured summary of fleet health, detected faults and recommended maintenance actions without requiring you to manage the platform day to day.
Planned Maintenance Within a Tight Schedule
Your challenge is planning maintenance work around a production schedule that leaves limited windows and a maintenance budget that has to be justified. Calendar-based servicing consumes resources on healthy motors while leaving degrading ones undetected. SignaTE tells you which motors need attention now, which are healthy and which are degrading at a rate that allows you to schedule intervention at the next planned stop. Work order integration with SAP PM and Maximo means fault alerts move directly into your existing maintenance planning workflow.
Accurate Detection, Full Coverage, Clean Integration
Your requirement is technical: accurate fault detection, low noise, coverage of motors that existing monitoring cannot reach and integration with the systems you already use. SignaTE uses ESA to detect rotor faults, bearing degradation and winding failures at the electrical signature stage, before any mechanical symptom develops. The per-motor AI baseline accounts for load profile, VFD harmonics and operating states, so the health score reflects genuine fault progression. Integration via OPC-UA, Modbus TCP and REST/Webhooks means SignaTE data flows into your DCS, SCADA, PI System or asset management platform. And because ESA is additive rather than a replacement for vibration monitoring, SignaTE extends your coverage without requiring you to dismantle an existing programme.
Start With Your Most Critical Motors
Every path starts with the motors that matter most to your plant. Choose the level of engagement that fits your current situation and your team's decision-making process.
Free 72-Hour Motor Health Check
A SignaTE field engineer installs on up to 5 critical motors, collects 72 hours of continuous ESA data with no plant shutdown and delivers a full motor health report within 7 days. No cost. No commitment.
Book a Demo
See the SignaTE dashboard, health score system and fault detection capabilities in a live walkthrough. Covers both the technical depth needed by reliability teams and the fleet-level view needed by operations leadership.
Request a 90-Day Pilot
Validate SignaTE's performance across your most critical motor population over 90 days. At the end of the pilot, the results show exactly what was detected, when it was caught and what it would have meant for your maintenance plan.
Book a Platform Walkthrough
A focused walkthrough of the SignaTE platform for engineering and operations teams who want to assess integration, dashboard capabilities and reporting outputs before proceeding to a health check or pilot.
Get in Touch
Talk to the SignaTE Team
To book a Free 72-Hour Motor Health Check, request a demo, enquire about the 90-Day Pilot Programme or ask a technical question about the SignaTE platform, contact the team directly or use the form.
SignaTE is a product of Tata Elxsi.