Analysis of electrical losses in machine-tools by using predictive maintenance thermography

This study examines electrical losses in a machine tool workshop using thermography as a predictive maintenance tool. The methodology involved a detailed thermographic inspection of the electrical systems of a compressor, milling machine, and lathe machine, identifying overheating and critical areas during operation. Findings revealed multiple faults, including air leaks, contractor overheating, and faulty electrical connections, all of which contributed to elevated energy consumption. Implementing corrective and preventive measures based on these thermographic insights led to notable energy savings, with estimated reductions of 0.363 kW·h for the milling machine, 0.341 kW·h for the compressor, and 0.322 kW·h for the lathe machine. These results highlight thermography's value in optimizing energy efficiency and emphasize predictive maintenance's role in enhancing operational efficiency and sustainability in industrial settings.