Harmonic diagnostic tool leading predictive maintenance
Harmonic diagnosis technology enables predictive maintenance of electrical equipment.
Issues in Equipment Maintenance Operations - Difficulties in technical inheritance of maintenance operations (aging workforce, reliance on individual skills) - Inspection work during busy periods is challenging due to the need for equipment shutdowns - Due to the presence of specialized and time-consuming inspection equipment, superficial measures such as replacing degraded parts have become the main focus. ↓ The solution to the above issues is predictive maintenance using harmonic diagnosis technology. 【Harmonic Diagnosis Technology】 This is a technology that utilizes harmonics from the secondary to the 40th order superimposed on the power supply current of electrical equipment to diagnose without stopping the equipment. After measuring harmonics from over 10,000 units of equipment for more than 10 years and disassembling and verifying the equipment, it was found that there is a strong correlation between the degradation points and degree of electrical equipment and the characteristics of the harmonics. The diagnostic devices using harmonic diagnosis technology are KS-3000A/KS-2000A and HM-3000AI. 【Features of the Harmonic Diagnostic Device】 1. Non-contact diagnosis: Collects harmonic components from the cable parts of the distribution board 2. Live-line diagnosis: Operates in the running state 3. Diagnosis possible without experts (AI analysis function): Evaluates diagnosis results on a five-point scale 4. Portable and easy to carry 5. Realization of predictive maintenance: Graphs the diagnosis results for trend management, enabling degradation prediction
basic information
【Size and Weight】 KS-3000A / KS-2000A: 250 (W) × 362 (D) × 150 (H) mm, 3.7 kg HM-3000A / HM-2000A: 250 (W) × 85 (D) × 100 (H) mm, approximately 2.0 kg 【Technical Advantages Not Found in Other Measuring and Diagnostic Instruments】 - Detection of abnormal operating conditions (installation issues, resonance, etc.) - Prediction of deterioration locations and timing (trend management using a three-point method) - Diagnosis of inverter operating conditions under live conditions - Calculation of motor efficiency from detection of air gap irregularities - Diagnosis of initial deterioration of motor insulation under live conditions 【Benefits of Implementation】 1. Cost Reduction: Review of planned maintenance due to extended replacement cycles and reduced inspection and maintenance. 2. Prevention of Troubles: Prevention of incidental failures and realization of predictive maintenance. 3. Improved Safety: Live measurement possible due to non-contact diagnosis. 4. Improved Quality: Maintenance of equipment performance and prevention of malfunctions in surrounding equipment. 5. Increased Reliability: Prevention of disasters and accidents, execution of planned production. 6. Increased Productivity: Reduction of defective products and total production maintenance. 7. Reduction of Waste from Faulty Equipment: Effective resource utilization through the 3Rs (Reduce, Reuse, Recycle).
Price information
KS-3000A: Dedicated to AC motors, starting at 6 million yen KS-2000A: Universal type for AC/DC and others, starting at 12.6 million yen HM-3000A: Successor to KS-3000A, starting at 4 million yen HM-3000AI: Successor to KS-3000A with AI functionality (Scheduled for release in December 2026: 6 million yen) HM-2000A: Successor to KS-2000A (Scheduled for sale in October 2026: 7 million yen) HM-2000AI: Successor to KS-2000A with AI functionality (Scheduled for release in March 2027: 9 million yen)
Price range
P6
Delivery Time
OTHER
Model number/Brand name
HM-3000AI、HM-2000AI／KS-3000A、KS-2000A
Applications/Examples of results
【Diagnosis Target Equipment】 1. AC Motors: Motor section, Load section, Inverter section 2. DC Motors: Motor section, Load section, Inverter section 3. Power Transformers: Molded transformers, Oil-filled transformers 4. Power Capacitors: Power factor correction capacitors 5. Generators: Diesel engines and turbines of prime movers 6. Uninterruptible Power Supply (UPS) 【Japan Mechatron's Harmonic Diagnostic Device is highly regarded.】 - 2005 Minister of Education, Culture, Sports, Science and Technology Award for Science and Technology (Technical Division) - 29th Invention Award from the Japan Invention Association (Yamaguchi Invention Contribution Award) - 2003 Kyoto City Small and Medium Enterprise Support Center Oscar Award - 2003 Japan Plant Maintenance Association Excellent Product Award
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