The State and Prospects of Technical Condition Diagnostics Methodsfor Electric Motors Considering the Digital Twin Concept

The rapid advancement of Industry 4.0 and the Internet of Things (IoT) has underscored the importance of effective diagnostics for electric motors, which are critical components in industrial, energy, and transportation systems. Traditional diagnostic methods, such as vibration, thermographic, and electromagnetic analyses, often lack adaptability and pre-dictive capabilities, limiting their ability to proactively identify faults under variable operating conditions. The digital twin concept, a virtual representation of physical assets synchronized with real-time sensor data, offers a transformative approach to technical condition monitoring. This paper reviews the state of diagnostic methods for electric mo-tors and evaluates the integration of digital twins to enhance diagnostic accuracy and pre-dictive maintenance. By leveraging platforms like Ansys Twin Builder and MATLAB/Simulink, digital twins enable real-time simulation, fault detection, and opera-tional optimization. The study proposes a novel methodology for diagnosing electric motor conditions using digital twins, incorporating mathematical modeling and real-time signal processing. Key findings include improved fault detection accuracy (MAE < 2.5%, RMSE < 3.1%) and the ability to simulate typical defects like rotor imbalance and insula-tion breakdown. The results demonstrate the potential of digital twins to revolutionize condition-based and predictive maintenance, offering scalable solutions for industrial applications. Future prospects include integrating machine learning for adaptive diagnos-tics and expanding digital twin applications to complex electromechanical systems.