The launch was unveiled at APIDEC 2025 in Abu Dhabi
ABB is transforming variable speed drives (VSDs) into a gateway for predictive maintenance across the entire powertrain. The service, launched at ADIPEC 2025 in Abu Dhabi, UAE, embeds Samotics-powered Electrical Signature Analysis (ESA) technology into legacy drives, allowing industrial players to collect performance-related data for analysis to provide maintenance teams with real-time insights
Embedding ESA technology enables advanced condition monitoring directly from the drive, providing insights into the health of the powertrain across motors, pumps, mixers, fans, and conveyors. Drives will be able to monitor and identify changes in operating behaviour, such as damage or bearing wear, coupling or gear misalignment or pump cavitation, so that remedial action can be taken before failure or downtime occurs.
Oswald Deuchar, global head of modernisation program, ABB Motion Services, said, "This leap forward in the modernisation of legacy drives promises to be a catalyst for the digital transformation of industry. It enables quick, seamless and cost-efficient adoption of ESA technology for enhanced uptime and immediate access to ABB's support and services. Should an issue be detected, our customers can rely on the full support of ABB's global expert network, including targeted actions to keep operations running consistently and reliably."
Simon Jagers, founder and co-CEO of Samotics, said, "Because ESA is embedded in the drive, it can monitor assets where other technologies struggle, such as submerged pumps or equipment in hot and toxic areas. This is a key step toward autonomous, self-optimising operations that are at the heart of the factory of the future."
The ESA-enabled drives gather electrical data from the powertrain. Powered by Samotics' analytics and supplied to industrial parties by ABB's global network, the data is translated into real-time insights on asset conditions, establishing a platform for actionable recommendations.
The ESA modernisation service will initially focus on two ranges of ABB's low-voltage VSDs- the cabinet-built drives ACS600 and ACS800. Recognising evolving industry requirements, the modernised drives will benefit from ABB's TÜV-certified cybersecurity measures.
As part of the ABB Ability Condition Monitoring suite of digital solutions and services, Samotics' ESA complements ABB's vibration analysis capabilities to deliver a complete view of powertrain health. Ranging from simple low-speed assets to high-speed systems, these solutions can ensure early fault detection, clearer service actions, and maximised reliability.
Deuchar said, "By embedding ESA directly into the modernised drives, we unlock predictive insights across the entire powertrain. This transforms drives into intelligent sensors that can detect changes in operating behaviour, enabling maintenance teams to anticipate potential faults before they can impact performance. This is one way we help industries to outrun, leaner, cleaner, and smarter."
