Application Case Study of Current Transducer in Industrial Motor Monitoring And Predictive Maintenance

A leading plastic packaging manufacturer （Hengda Sujiao）was facing repeated production interruptions caused by unexpected motor failures in its extrusion lines. Each shutdown resulted in material waste, delayed shipments, and higher maintenance expenses. Traditional protection devices such as circuit breakers could only trip during severe faults, but they could not detect gradual overload, phase imbalance, or abnormal current fluctuations. To improve reliability and reduce risk, the company introduced a comprehensive monitoring solution based on a high accuracy current transducer system supplied by Hubei Tianrui Electronic Co., Ltd.

In this project, AC transducer units were installed on the three phase power lines of critical extrusion motors. Each AC current transducer measured real time load current and converted it into a standard 4 to 20 mA output signal, which was transmitted to the plant PLC and SCADA system. By integrating these signals into the monitoring platform, engineers could observe true RMS current values, trend curves, and alarm thresholds for each production line.

Shortly after installation, the system detected a steady increase in motor operating current during peak production hours. Although the motor temperature remained within acceptable limits, the current transducer data showed clear signs of overload and harmonic distortion. Using this information, the maintenance team conducted a targeted inspection and discovered excessive mechanical friction in the screw assembly. Early intervention prevented a major breakdown and saved significant repair costs.

This application highlights the importance of industrial current monitoring solutions such as DIN rail current transducer modules, three phase AC current transducer systems, and isolated current signal converters for PLC integration. In addition to motor monitoring, similar solutions can be applied to power distribution panel monitoring, energy management systems, HVAC current measurement, and renewable energy inverter current detection.

Hubei Tianrui Electronic Co., Ltd. provided a customized solution tailored to the plant’s load range and installation environment. Their AC transducer products feature high accuracy measurement, strong anti interference capability, wide input range, and reliable electrical isolation. The compact design allows easy installation in control cabinets, while optional voltage output or current output configurations support flexible system integration. For customers requiring OEM current transducer solutions or customized current sensor modules, the company offers design support and fast production capability.

After implementing the current transducer based monitoring system, the manufacturer reduced unplanned downtime by more than 30 percent and improved overall equipment efficiency. Energy consumption analysis also helped optimize motor load distribution and reduce electricity costs.

This case demonstrates how advanced AC current transducer technology is not only a measurement tool but also a strategic solution for predictive maintenance, industrial automation, and intelligent power monitoring. With professional support from Hubei Tianrui Electronic Co., Ltd., businesses can achieve safer operation, higher efficiency, and long term cost savings through precise and reliable current measurement solutions.