High maintenance costs and production losses arise from unexpected VFD failures. Failures in expensive VFDs directly impact motors, drives, and overall process availability. Faclon Labs provides continuous VFD health monitoring using electrical and thermal parameters
Continuous monitoring of IGBT temperature, motor loading, faults, and electrical parameters
Automated health diagnostics highlighting abnormal trends and degradation patterns
Proactive maintenance actions driven by real-time alerts and condition insights
Quantifiable gains in drive reliability, uptime, and maintenance performance
Up to 30% Less Sudden Downtime
Early alerts allow repairs during planned windows, eliminating nearly a third of all unexpected emergency breakdowns
Up to 20% Better VFD Life Cycle
Real-time IGBT stress monitoring prevents heat damage, extending the operational life of high-cost power electronics
Less Manual Inspection Reliance
Automated data streams eliminate routine logging, allowing teams to focus on high-impact strategic reliability tasks
Up to 5% Lower Production Loss
Continuous drive availability prevents cascading output losses and material waste triggered by unexpected process trips
Solution Highlights
Core capabilities enabling continuous monitoring and early VFD failure detection
Unified VFD Dashboard
Centralized dashboard displaying health status, trends, diagnostics, and alerts
Thermal Monitoring
Continuous monitoring of critical temperatures including IGBT and drive components
Fault Analytics
Advanced analytics identifying recurring faults and abnormal operating conditions
Multi-Vendor Compatibility
Gateways supporting integration with VFDs from any manufacturer
Smart Alerting System
SMS and email alerts enabling rapid response to emerging VFD issues
Automated Reporting
Scheduled reports highlighting health status of all monitored VFDs
Why Faclon Labs
Differentiators that ensure dependable and scalable VFD health monitoring
AI and LLM Capabilities
Build custom diagnostics and query VFD insights via conversational AI interfaces
Unified Maintenance Platform
A single platform supporting VFD, CBM, and diverse reliability use cases
Flexible Customization
Tailored configurations aligned to specific customer VFD operating conditions
Proven Industrial Deployments
Successfully implemented across power plants, chemicals, and heavy industries
Cybersecurity Compliant Design
Meets all necessary OT and IT cybersecurity standards for industrial data safety
Customer Success Focus
Dedicated support ensuring reliable operation and sustained platform adoption
CASE STUDY - VFD HEALTH MONITORING
Improving Drive Availability Across Five Power Plants Using Proactive VFD Monitoring
The project involved monitoring over 1000 sensors across 400 VFD-driven industrial assets. This comprehensive deployment provided real-time health visibility across five critical power plants. The implementation focused on proactive health monitoring to eliminate sudden drive-related failures
ROI < 1 Year Investment was recovered through the prevention of expensive drive replacements and downtime
5% Increase in Asset Availability Continuous monitoring ensured higher uptime by resolving VFD issues before they halted production
Improved Maintenance Team Capability Technical teams leveraged automated analytics to shift from reactive repairs to predictive maintenance
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