ABB launches embedded ESA technology in drives, turning modernization into a digital catalyst

ABB is raising the bar regarding the modernization of variable speed drives (VSDs), transforming them into a gateway for predictive maintenance of the entire powertrain. The service, launched = at ADIPEC 2025 in Abu Dhabi, UAE, embeds Samotics-powered Electrical Signature Analysis (ESA) technology into legacy drives. This enables industrial players to collect performance-related data, which can then be analyzed to provide maintenance teams with actionable, real-time insights on the condition of their assets.

Embedding ESA technology unlocks advanced condition monitoring - directly from the drive - providing insight into the health of the powertrain across assets such as motors, pumps, fans, mixers, and conveyors. Drives will now be able to monitor and identify changes in operating behaviour, such as bearing wear or damage, coupling or gear misalignment or pump cavitation. This means that remedial action can be taken well before a costly failure and/or long downtime can occur.

The ESA-enabled drives gather electrical data directly from the powertrain. Powered by Samotics’ analytics and supplied to industrial players by ABB’s global expert network, the data are translated into real-time insights on asset conditions. This establishes a solid platform for actionable recommendations and a clear path forward, freeing up skilled labour and maximizing uptime, for operational resilience.

Initially, the ESA modernization service will focus on two ranges of ABB’s low-voltage (LV) VSDs — the cabinet-built drives ACS600 and ACS800. In recognition of evolving industry requirements, the modernized drives also benefit from ABB’s TÜV-certified cyber security measures.

As part of the ABB Ability™ Condition Monitoring suite of digital solutions and services, Samotics’ ESA complements ABB’s well-established vibration analysis capabilities to provide the most complete view of powertrain health. From simple low-speed assets to complex, high-speed systems, these two solutions ensure early fault detection, clearer service actions and maximized reliability.