Multidisciplinary Journal Epistemology of the Sciences
Volume 2, Issue 2, 2025, April–June
DOI: https://doi.org/10.71112/nchv3d08
ANALYSIS OF ELECTRICAL LOSSES IN MACHINE-TOOLS BY USING
PREDICTIVE MAINTENANCE THERMOGRAPHY
ANÁLISIS DE PÉRDIDAS ELÉCTRICAS EN MÁQUINAS-HERRAMIENTAS
MEDIANTE LA APLICACIÓN DE MANTENIMIENTO PREDICTIVO DE
TERMOGRAFÍA
Angel Isaac Simbaña Gallardo
Edison Walter Intriago Ponce
Cristian Orlando Guilcaso Molina
Julio David Saquinga Daquilema
Ecuador
DOI: https://doi.org/10.71112/nchv3d08
1026 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Analysis of electrical losses in machine-tools by using predictive maintenance
thermography
Análisis de pérdidas eléctricas en máquinas-herramientas mediante la aplicación
de mantenimiento predictivo de termografía
Angel Isaac Simbaña Gallardo
1
isimbana@tecnológicosucre.edu.ec
https://orcid.org/0000-0002-3324-3071
Instituto Superior Universitario Sucre
Ecuador
Edison Walter Intriago Ponce
2
eintriagop@est.ups.edu.ec
https://orcid.org/0000-0001-7516-5123
Universidad Politécnica Salesiana
Ecuador
Cristian Orlando Guilcaso Molina
3
cristian.guilcaso6706@utc.edu.ec
https://orcid.org/0000-0003-4745-8951
Universidad Técnica de Cotopaxi
Ecuador
Julio David Saquinga Daquilema
4
dsaquinga@tecnologicosucre.edu.ec
http://orcid.org/0000-0001-8353-1621
Instituto Superior Universitario Sucre
Ecuador
ABSTRACT
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
DOI: https://doi.org/10.71112/nchv3d08
1027 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
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.
Keywords: energy efficiency; predictive maintenance; thermography; electrical losses;
machine-tool
RESUMEN
Este estudio tiene como objetivo analizar las pérdidas eléctricas en un taller de máquinas-
herramienta mediante el uso de la termografía como técnica de mantenimiento predictivo. La
metodología incluyó una inspección detallada de los sistemas eléctricos de un compresor, una
fresadora y un torno, mediante una cámara termográfica para identificar sobrecalentamientos y
puntos críticos en condiciones de operación. Los resultados mostraron diversas fallas, como
fugas de aire, sobrecalentamiento en contactores y conexiones eléctricas defectuosas, lo cual
contribuyó al consumo energético excesivo de estos equipos. Al implementar actividades
correctivas y preventivas basadas en los hallazgos termográficos, se lograron mejoras
significativas, con ahorros energéticos estimados de hasta 0.363 kW·h en la fresadora, 0.341
kW·h en el compresor y 0.322 kW·h en el torno. Estos resultados subrayan la efectividad de la
termografía en la optimización energética y refuerzan la importancia del mantenimiento
predictivo para mejorar la eficiencia y sostenibilidad en entornos industriales.
Palabras clave: eficiencia energética; mantenimiento predictivo; termografía; pérdidas
eléctricas; máquinas-herramientas
Received: May 31, 2025 | Accepted: June 16, 2025
DOI: https://doi.org/10.71112/nchv3d08
1028 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
INTRODUCTION
The increase in electrical energy consumption in machine tool workshops is largely due
to rising production demands, which require extended and continuous operation of equipment
(Scharnhorst et al., 2024). Factors such as machine aging, component wear, and inadequate
maintenance contribute to inefficient energy use, as machinery operates under less-than-ideal
conditions that demand more power for standard tasks (Chang et al., 2021).
Outdated technology in certain machines also prevents optimal energy utilization,
exacerbating consumption levels. This escalation in energy use is linked to issues such as
electrical losses and component overheating, which accelerate equipment wear and increase
failure frequency. These inefficiencies drive up operating costs, with significant increases in
electricity bills for workshops with intensive machinery use. Additionally, accelerated wear due
to inefficient operation shortens equipment life and raises maintenance and replacement
expenses. Environmentally, higher energy consumption contributes to greater emissions,
especially in areas reliant on fossil fuels for electricity generation, thus impacting climate change
(Rahman et al., 2022).
Detecting and addressing electrical energy losses in industrial settings, particularly in
machine tool workshops, is essential for economic, operational, and environmental reasons.
Energy losses represent unnecessary resource usage, which directly impacts operational costs
(Bosu et al., 2023). In workshops with power-intensive machinery, such as lathes, milling
machines, and Computer Numerical Control systems (CNC), even minor inefficiencies
accumulate into substantial energy waste, affecting overall profitability. Effective identification
and correction of these losses improve energy use, reduce electricity costs, and optimize
resource management for the workshop (Himeur et al., 2021).
Operationally, energy losses frequently signal deeper equipment issues, including faults
in electrical components such as motors, cables, frequency converters, and control systems, as
DOI: https://doi.org/10.71112/nchv3d08
1029 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
well as mechanical wear that can increase friction or cause misalignment. For instance, a
machine motor operating inefficiently due to overheating or faulty connections not only
consumes excessive energy but is also at risk of permanent damage. Laouadi et al. (2020)
demonstrated that early detection of such issues by monitoring and correcting energy losses
facilitates more effective preventive and predictive maintenance, reducing unplanned downtime
and extending equipment lifespan.
From a sustainability standpoint, addressing energy losses also brings significant
environmental benefits. Bogdanov et al. (2021) examined the transition toward more sustainable
electricity generation, noting that fossil-fuel reliance in energy production contributes to
greenhouse gas emissions. Therefore, any reduction in energy usage directly reduces the
carbon footprint of a workshop and the broader industry. As environmental responsibility grows
in importance, energy efficiency practices not only help to cut costs but also support regulatory
compliance and enhance corporate reputation.
By employing predictive maintenance techniques like thermography, which enables real-
time detection of thermal anomalies and energy inefficiencies, workshops can implement
strategies that are both sustainable and efficient. This approach aligns productivity with
environmental stewardship, making energy management an integral part of achieving
operational excellence. In sum, the identification and mitigation of electrical energy losses in
machine tool workshops represent a strategic pathway toward economic efficiency, enhanced
operational reliability, environmental sustainability, and high production quality.
Predictive maintenance is a strategy defined by Falekas and Karlis (2021) that relies on
continuous or periodic monitoring of equipment conditions to detect signs of deterioration or
impending failures before they occur. Unlike preventive maintenance, which occurs at set
intervals, predictive maintenance intervenes only when data suggests a failure is imminent. This
approach helps optimize downtime, minimize repair costs, and extend equipment life by
DOI: https://doi.org/10.71112/nchv3d08
1030 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
ensuring interventions happen only when necessary (Antonino-Daviu, 2020). Predictive
maintenance plays a vital role in preventing failures in machine tools by facilitating early
identification of issues. By continuously monitoring the equipment's condition, early signs of
wear or malfunction in critical components can be detected, enabling timely interventions that
reduce unexpected downtimes and enhance equipment availability. Additionally, it reduces
unnecessary energy consumption associated with malfunctioning components (Hoffmann et al.,
2020).
Thermography is a predictive maintenance technique that uses thermal imaging to detect
temperature anomalies in equipment (Venegas et al., 2022). It involves the use of
thermographic cameras to capture infrared radiation emitted by objects, converting it into a
visible image where varying temperatures are represented by different colors. This technique is
especially valuable in industrial settings, as it can identify components operating at abnormal
temperatures, signaling problems like excessive friction, poor insulation, loose electrical
connections, circuit overloads, or motor and transmission failures.
According to Balakrishnan et al. (2022), thermography works by detecting infrared
radiation, which is emitted by all objects based on their temperature. Higher temperatures
correspond to greater infrared radiation emissions, which the thermographic camera detects
and converts into a thermal image. This contrast makes it possible to quickly identify problem
areas that may not be visible through conventional inspection.
The thermographic camera is a key tool for detecting electrical leaks, which are a major
cause of energy losses and failures in industrial electrical systems. These leaks typically
manifest as temperature increases in affected areas due to unwanted current flow through faulty
materials or connections (Valencia-Bacilio et al., 2023). Thermography, with its high precision in
detecting temperature differences, enables the identification of these leaks in components such
as cables, distribution boards, and transformers without interrupting equipment operation. Its
DOI: https://doi.org/10.71112/nchv3d08
1031 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
application is essential for preventing significant issues like short circuits, fires, or equipment
damage. Thus, thermographic cameras play a critical role in optimizing predictive maintenance,
managing energy consumption, and preventing electrical risks, thereby enhancing the safe and
efficient operation of industrial systems (Ortega et al., 2021).
Hadziefendic et al. (2020) emphasized the importance of periodic thermographic
inspections. Targeting critical components like motors, variable speed drives, or transmission
systems allows the identification of temperature patterns indicating potential problems. For
example, a motor running at higher temperatures may signal overheating, overloading, or
internal friction, while hot spots in a variable-speed drive could indicate faulty connections or
damaged parts. If left unaddressed, these thermal anomalies can reduce energy efficiency,
increase electricity consumption, and decrease overall machine performance.
This study aims to identify and reduce electrical losses in a machine tool workshop by
applying thermography as a predictive maintenance technique. The methodology enables the
non-invasive detection of critical heat points in electrical systems, helping identify overheating
and energy losses before they lead to major damage or reduced equipment efficiency,
facilitating necessary corrective actions. The paper is structured as follows: the Methodology
section outlines the data collection process for machines in both operational and idle conditions.
The Results section details the corrective and preventive actions based on the identified issues,
with a focus on energy efficiency. In the Discussion, comparisons with existing literature are
made, highlighting the significance and originality of this study. The Conclusions section
synthesizes the key findings of the work.
METHOLOGY
The experimental method involves the collection of data through observation and
measurement of variables in controlled or natural settings. In this case, data was collected on-
DOI: https://doi.org/10.71112/nchv3d08
1032 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
site, meaning the research was conducted in the actual environment where the machines
operate. This approach allows for the capture of operational parameters and the real
performance of the equipment. During the investigation, specific measuring devices, such as
multimeters, ammeters, and a thermographic camera, were used to monitor key operational
parameters like current, voltage, and temperature. This data helps identify primary electrical
faults and establish correlations between machine performance and operational conditions. By
applying the experimental method, the research addresses practical issues, contributing to
improvements in efficiency and safety within electrical installations.
Three machines in the workshop have accumulated the most operating hours, suggesting
they have been in continuous use for extended periods and may require a thorough review to
detect potential electrical and mechanical faults. The first machine is a 5.5 HP double-piston
compressor, designed to deliver an airflow of 500 L/min and reach a maximum pressure of 180
psi. This makes it suitable for applications requiring high-pressure compressed air. The
compressor is equipped with a three-phase induction motor, operating at a current of 13.9 A and
a voltage of 220 V. Its transmission system uses a double pulley to allow for the adjustment of
operational speed and torque, optimizing its performance under varying load conditions. A
detailed analysis of electrical parameters was conducted, including voltage and current
measurements to ensure the equipment is operating within the manufacturer’s recommended
limits. Voltage readings showed a value close to the nominal, registering 218.2 V from the main
distribution board, as shown in Figure 1.
DOI: https://doi.org/10.71112/nchv3d08
1033 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Figure 1
Measuring compressor motor voltage
This voltage is appropriate for the motor's operation, indicating a stable power supply.
During the air compression process, when the compressor activates to pressurize the system, a
current of 13.82 A was measured. This value is slightly lower than the specified value,
suggesting that the motor is operating efficiently without significant electrical overload during
this cycle. This is important for diagnosing the machine’s health, as the amperage within the
recommended range reduces the risk of overheating and potential electrical failures that could
affect the equipment's durability. These operational data are essential for evaluating the
compressor’s performance and stability, serving as a reference for implementing predictive
maintenance strategies that can prevent failures and extend the lifespan of this critical machine
in the workshop.
Figure 2a shows the electrical system installation diagram designed for the proper
connection and operation of the double-piston compressor, highlighting the arrangement of
control and protection elements such as the contactor, breaker, and power supply lines. This
setup ensures both efficient operation and the safety of the equipment and work environment. It
is important that the configuration minimizes electrical risks while guaranteeing that the
DOI: https://doi.org/10.71112/nchv3d08
1034 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
compressor receives the voltage and current specified by the manufacturer during each
compression cycle. To assess the condition of the electrical components under real operating
conditions, thermography was used to inspect the compressor’s contactor while it was running.
During the analysis, a temperature rise was detected at the connection terminals of the
compressor's breaker, as shown in Figure 2b. This increase in temperature indicates additional
resistance at the connections or potential loosening of the contact points. These issues could
lead to localized overheating, which, if left unaddressed, may result in a more severe electrical
failure or even a fire hazard. This finding underscores the need for preventive or corrective
maintenance measures to ensure the safe and continuous operation of the compressor in the
workshop.
Figure 2
Compressor contactor, a) installed, b) thermography
Regarding the machine tools available in the workshop, there is a versatile universal
milling machine capable of performing various cutting and finishing operations on materials such
as steel, aluminum, and other metals. It is equipped with a three-phase motor operating at 220
V, consuming 6.5 A, with 2 HP of power, making it suitable for a wide range of machining tasks.
To assess the operational condition of the milling machine and detect potential electrical faults,
DOI: https://doi.org/10.71112/nchv3d08
1035 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
a thermographic camera was used, and the initial analysis is shown in Figure 3a. This device
enabled the visualization of surface temperatures of electrical components, helping identify
overheating areas or potential issues in the electrical system.
Upon analyzing the thermographic image, a significant temperature rise was observed in
the electrical conductors, indicating additional resistance or a defect in the connection, which is
generating heat. This can lead to insulation degradation, increasing the risk of short circuits or
serious electrical failures. A detailed inspection of these conductors revealed noticeable wear on
the insulation, particularly in terms of the thickness of the protective material. This wear can
expose parts of the conductor, which not only increases the risk of short circuits but also
compromises the safety of the personnel operating the machine.
Additionally, Figure 3b shows overheating in the milling machine's contactor, which is
caused by improper connections where adhesive tape was used instead of proper terminals or
connectors. This is an unsafe practice as it does not ensure a secure connection or adequate
resistance to the current. Such overheating could indicate poor installation or an improvised
repair that fails to meet the necessary safety and efficiency standards for this type of equipment.
This underscores the importance of performing both preventive and predictive maintenance to
reduce the milling machine's energy consumption, avoid operational disruptions, and ensure the
safety of both the personnel and the equipment.
DOI: https://doi.org/10.71112/nchv3d08
1036 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Figure 3
Analysis of electrical connections on the milling machine, a) visual inspection, b)
thermography
During the operation of the milling machine, higher-than-expected electrical consumption
was recorded, as shown in Figure 4. A detailed visual inspection revealed several issues with
the electrical conductors, including sections of cables lacking proper insulation and improper
splicing, compromising the quality of the connection.
Figure 4
Power consumption of the milling machine in use.
DOI: https://doi.org/10.71112/nchv3d08
1037 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Additionally, the insulating tape used in the splices was found to be burnt, indicating it
could not withstand the operating conditions, contributing to overheating and excessive
electricity consumption. These insulation and splicing problems negatively affect the milling
machine's energy efficiency, posing a significant risk of electrical failures and potential damage
to the equipment.
The next machine tool to be analyzed is a parallel lathe, equipped with a 2 HP three-
phase motor operating at 220 V. Several risks have been identified when operating the lathe
under current conditions. One major concern is the motor, which tends to overheat excessively
during operation, as shown in Figure 5a. This overheating indicates that the motor is functioning
outside its optimal parameters, potentially reducing its lifespan and compromising the safety of
both the machine and its operators.
A particularly concerning finding is that, even when the machine is off, the electrical
consumption does not drop to an insignificant level, as would be expected. Instead, a current
draw of 1.2 A is observed, suggesting a potential current leak or a component that continues to
consume power while in idle mode. This electrical loss could be attributed to issues with the
motor's disconnect system or wiring problems, which not only increase electrical consumption
but also present a risk of overheating or short circuits. Additionally, when inspecting the
electrical connections while the lathe is in operation, particularly during machining, an unusual
increase in temperature was detected in the electrical panel, as shown in Figure 5b. This
temperature rise may indicate poor connections or improper current distribution within the panel,
leading to increased resistance and energy loss.
DOI: https://doi.org/10.71112/nchv3d08
1038 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Figure 5
Analysis of electrical connections on the lathe, a) visual inspection, b) thermography
RESULTS
After reviewing and analyzing the collected data, a comprehensive maintenance plan was
developed, incorporating corrective, preventive, and predictive activities aimed at improving
electrical energy consumption and ensuring the safe operation of the machines. The plan began
with interventions on the compressor, where issues in wiring and contactor connections were
identified. Corrective maintenance focused on addressing existing faults affecting the
compressor’s performance. This involved repairing and replacing defective cables with worn or
incomplete insulation, which were causing electrical losses. Additionally, the contactors were
readjusted, as they were not closing properly, resulting in small current leaks. Precise
adjustments ensured a firm and stable connection.
Loose connections were also found, increasing resistance and causing overheating.
These were tightened to improve the current flow. These corrective interventions led to an
immediate reduction in electricity consumption when the compressor was off, eliminating energy
leaks and improving operational safety, as shown in Figure 6. Preventive maintenance, on the
other hand, was designed to reduce the risk of future failures and improve energy consumption
DOI: https://doi.org/10.71112/nchv3d08
1039 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
through scheduled activities. One of the preventive tasks involved cleaning and organizing the
wiring system, which helped prevent friction damage and improved airflow, reducing the risk of
overheating. In addition, regular inspections of insulation on conductors and connections were
implemented, as deteriorating insulation can cause current leakage and increase the risk of
short circuits.
Figure 6
Review of zero energy consumption of the compressor in an idle state.
The use of the thermal imaging camera in this context provided an accurate assessment
of the compressor’s operating conditions and its components, enabling the identification of
issues that might not be easily detected with conventional methods. The thermal camera
visualized the heat generated by the functioning components, making it easier to spot
anomalies such as air leaks and overheating areas. This provided important data for diagnosing
and correcting faults. Issues like inadequate sealing or improper adjustment of connections
were impacting the compressor’s efficiency and posing risks to both energy consumption and
system safety. The thermal camera’s ability to highlight these leaks allowed for immediate
corrective actions.
DOI: https://doi.org/10.71112/nchv3d08
1040 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Figure 7a illustrates the verification process of the coupling adjustments and the condition
of the compressor’s air outlet components. A thorough inspection of these parts was vital to
ensure proper sealing and adjustments. After making these corrections, another inspection with
the thermal camera was conducted, as shown in Figure 7b, confirming that the previously
detected air leaks were no longer present. This confirmed the effective resolution of the issues
related to the mechanical couplings.
Figure 7
Maintenance of mechanical connections in the compressor, a) verification of adjustment in
accessories, b) preventive thermography
Previously, it was observed that the compressor was experiencing significant pressure
loss, even when idle. The compressor was set to maintain a pressure of 125 psi, but this
pressure continually dropped to 90 psi, as shown in Figure 8a, triggering the compressor to
restart and reach the set pressure. The pressure system was regulated by a pressure switch, as
shown in Figure 8b, which controlled the compressor's on-and-off cycles based on the internal
pressure of 125 psi. However, due to air leaks in the mechanical couplings and improperly
adjusted connections, the compressor had to run continuously to restore the lost pressure. This
DOI: https://doi.org/10.71112/nchv3d08
1041 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
not only increased energy consumption but also caused frequent on/off cycles, impacting overall
performance.
Figure 8
Compressor pressure gauge, a) pressure loss previously, b) stability of the set pressure after
maintenance activities.
Corrective actions, including inspecting, adjusting, and replacing defective couplings and
improving component connections, resolved these air leaks. With the leaks fixed, the
compressor no longer needed to run continuously to maintain pressure, leading to significant
energy savings. As a result of these corrections, an estimated energy savings of 0.341 kW·h
was achieved, improving compressor efficiency and contributing to a reduction in operational
costs associated with electrical consumption.
For the milling machine, targeted corrective actions were implemented to resolve
previously identified electrical issues. The defective contactor, which had been causing
overheating and unnecessary power consumption, was replaced. Additionally, conductor routing
was reorganized to ensure proper channeling and protection. Following these adjustments,
electrical consumption for the milling machine dropped from 7.1 A to 6.47 A, aligning more
closely with the manufacturer’s recommended maximum, as depicted in Figure 9a. This
amperage reduction demonstrates that the improvements had a positive impact on the
machine’s energy efficiency, performance, and prevented excessive power use.
DOI: https://doi.org/10.71112/nchv3d08
1042 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
A thermographic camera was used to verify these improvements, with Figure 9b
displaying the thermographic analysis results. The analysis confirmed that the previously
observed hot spots, which indicated areas of overheating, were no longer present. This visual
confirmation underscores that issues related to overheating and energy loss were effectively
resolved, contributing to a safer and more efficient operation of the equipment. These corrective
measures are estimated to achieve energy savings of 0.363 kW·h, enhancing the milling
machine's operational efficiency and yielding direct benefits in reduced operational costs and
environmental impact.
Figure 9
Maintenance activities on the milling machine, a) correct amperage measurement, b)
thermography
An overcurrent factor of 1.09 was identified in the lathe, indicating a 9% increase in
electrical consumption due to faults in its electrical system. This overconsumption signaled a
malfunction, causing the lathe to use more energy than necessary. This not only reduced
operational efficiency and raised energy costs but also risked accelerated wear of the electrical
components.
DOI: https://doi.org/10.71112/nchv3d08
1043 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Further analysis identified the lathe's contactor as the primary issue, showing signs of
overheating—likely due to accumulated internal wear from prolonged use. This defect limited
the contactor’s performance, increasing electrical resistance and thus raising energy
consumption. Corrective maintenance involved replacing the faulty contactor with a new one,
which was installed and tested in the lathe’s electrical panel, as shown in Figure 10a. This
replacement eliminated the overheating and improved the lathe’s overall electrical efficiency,
allowing it to operate within the recommended energy parameters.
A follow-up inspection using a thermal camera verified the results of the corrective
actions. Figure 10b shows the thermographic analysis, confirming the absence of hotspots in
the lathe’s electrical system. These improvements resulted in an estimated energy saving of
0.322 kW·h, enhancing operational efficiency and reducing energy costs. Moreover, replacing
the contactor and correcting the electrical faults help extend the equipment's lifespan,
preventing potential failures or severe damage that could have occurred if left unaddressed.
Figure 10
Maintenance activities on the lathe, a) corrective on the contactor, b) predictive with
thermography
DOI: https://doi.org/10.71112/nchv3d08
1044 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
DISCUSSION
The study focused on three main machines, starting with a compressor that showed
significant air leaks and inefficient operation, leading to unnecessary energy use, particularly
while the compressor was off. Figure 11 illustrates how energy consumption changed after
applying predictive maintenance based on thermographic inspections to three machine tools: a
compressor, a milling machine, and a lathe. After addressing issues like overheating, air leaks,
and poor electrical connections, a noticeable drop in power usage was observed, highlighting
the practical benefits of using thermography to detect and resolve energy-related faults in
industrial equipment. Electrical connections on a universal milling machine were also evaluated,
where overheating in the contactor due to faulty wiring was detected. By replacing the contactor
and organizing the conductors, energy savings of approximately 0.363 kW·h were achieved.
Finally, an analysis of a parallel lathe identified a 9 % overcurrent factor, which was increasing
energy consumption. Replacing the defective contactor and performing a thermographic
inspection eliminated overheating and reduced power usage by 0.322 kW·h.
Figure 11
Electric consumption
DOI: https://doi.org/10.71112/nchv3d08
1045 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
The study reviewed existing research on energy efficiency and thermography in
predictive maintenance for electrical equipment. Alvarado-Hernandez et al. (2022) utilized
thermography to identify overheating in electric motors, resulting in reduced energy losses post-
intervention, resounding the savings estimated in this study. Both studies underscore
thermography as an effective predictive maintenance tool in manufacturing. Similarly, Venegas
et al. (2020) emphasized that identifying thermal anomalies, such as hotspots and component
overheating, enables timely correction, which reduces energy consumption. This technique has
proven essential for failure prevention, energy conservation, and extending equipment lifespan,
benefits mirrored in the assessment of the compressor, milling machine, and lathe.
Seabra-Paiva et al. (2019) used thermography to evaluate energy efficiency in industrial
electric motors, showing that early fault detection and correction can lead to considerable
energy savings. This study’s results align with those findings, reinforcing thermography as a
predictive maintenance tool that enhances energy efficiency in machine tools. The observed
reduction in energy consumption after addressing electrical issues supports the potential for
meaningful energy savings using this approach. Similarly, Firdaus et al. (Firdaus et al., 2023)
used thermography to identify hotspots and overheating in machine tool electrical systems, also
highlighting its value in improving efficiency.
Most reviewed studies, such as Piselli et al. (2024), focus on thermography applications
in large-scale equipment. However, this study emphasizes its unique applicability to smaller
machinery like lathes and milling machines, which present particular challenges in detecting and
resolving electrical issues for energy optimization. While some research broadly discusses
improvements in energy efficiency, this study provides specific quantitative savings by analyzing
energy consumption before and after intervention.
Future research could expand to a diverse range of equipment types, power levels, and
industrial applications, assessing not only energy efficiency gains but also impacts on machine
DOI: https://doi.org/10.71112/nchv3d08
1046 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
performance and operational costs. Moreover, combining thermography with other predictive
maintenance techniques, such as vibration and oil analysis, could provide a more
comprehensive equipment assessment, further enhancing maintenance effectiveness and cost
efficiency.
CONCLUSIONS
The application of thermography as a predictive maintenance technique has shown a
marked improvement in the energy efficiency of the analyzed machine tools. Specifically,
addressing detected electrical issues, such as air leaks in the compressor, overheating in the
milling machine and lathe contactors, and improving electrical connections, resulted in
estimated energy savings of 0.341, 0.363, and 0.322 kW·h, respectively. These findings
emphasize thermography’s effectiveness in identifying potential issues before they escalate,
supporting both the extended lifespan of equipment and more energy-efficient operations.
Thermography has demonstrated itself as an efficient, non-invasive tool for industrial
electrical inspections, enabling the detection of hotspots, overheating, and faulty connections
that may not be visible through standard visual inspections. The thermographic images obtained
provided essential insights into fault identification, such as degraded insulating coatings and
suboptimal electrical connections, allowing for precise corrective actions. This confirms
thermography's value as a key tool in predictive maintenance and energy efficiency
management within industrial environments.
This study highlights the value of a comprehensive maintenance approach, integrating
both preventive and corrective actions to resolve issues impacting the energy efficiency of
machine tools. Corrective actions, like replacing defective contactors and optimizing electrical
system configurations, along with continuous monitoring through thermography, have effectively
reduced unnecessary energy consumption. These practices not only optimize energy resources
DOI: https://doi.org/10.71112/nchv3d08
1047 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
but also enhance operational sustainability, addressing the modern industry’s increasing
demand for energy-efficient solutions.
Conflict of Interest Statement
The authors declare that they have no conflict of interest related to this research.
Authorship Contribution Statement
Angel Isaac Simbaña Gallardo: investigation, conceptualization, methodology, project
administration, writing – original draft, writing – review and editing.
Edison Walter Intriago Ponce: methodology, investigation, supervision, writing – original draft
Cristian Orlando Guilcaso Molina: investigation, supervision, writing – review and editing.
Julio David Saquinga Daquilema: formal analysis, writing – review and editing.
Artificial Intelligence Usage Statement
The authors declare that they used Artificial Intelligence as a support tool for this article,
and also affirm that this tool does not in any way replace the intellectual task or process. After
rigorous reviews with different tools confirming the absence of plagiarism, as evidenced in the
records, the authors declare and acknowledge that this work is the result of their intellectual
effort and has not been written or published on any electronic or AI platform.
REFERENCES
Alvarado-Hernandez, A., Zamudio-Ramirez, I., Jaen-Cuellar, A., Osornio-Rios, R., Donderis-
Quiles, V., & Antonino-Daviu, J. (2022). Infrared thermography smart sensor for the
condition monitoring of gearbox and bearings faults in induction motors. Sensors, 22(16),
6075. https://doi.org/10.3390/s22166075
Antonino-Daviu, J. (2020). Electrical monitoring under transient conditions: A new paradigm in
electric motors predictive maintenance. Applied Sciences, 10(17),
6137. https://doi.org/10.3390/app10176137
DOI: https://doi.org/10.71112/nchv3d08
1048 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Balakrishnan, G., Yaw, C., Koh, S., Abedin, T., Raj, A., Tiong, S., & Chen, C. (2022). A review
of infrared thermography for condition-based monitoring in electrical energy: Applications
and recommendations. Energies, 15(16), 6000. https://doi.org/10.3390/en15166000
Bogdanov, D., Ram, M., Aghahosseini, A., Gulagi, A., Oyewo, A., Child, M., Caldera, U.,
Sadovskaia, K., Farfan, J., De Souza-Noel, L., Fasihi, M., Khalili, S., Traber, T., &
Breyer, C. (2021). Low-cost renewable electricity as the key driver of the global energy
transition towards sustainability. Energy, 227,
120467. https://doi.org/10.1016/j.energy.2021.120467
Bosu, I., Mahmoud, H., & Hassan, H. (2023). Energy audit and management of an industrial site
based on energy efficiency, economic, and environmental analysis. Applied Energy, 333,
120619. https://doi.org/10.1016/j.apenergy.2022.120619
Chang, M., Thellufsen, J., Zakeri, B., Pickering, B., Pfenninger, S., Lund, H., & Ostergaard, P.
(2021). Trends in tools and approaches for modelling the energy transition. Applied
Energy, 290, 116731. https://doi.org/10.1016/j.apenergy.2021.116731
Falekas, G., & Karlis, A. (2021). Digital twin in electrical machine control and predictive
maintenance: State-of-the-art and future prospects. Energies, 14(18),
5933. https://doi.org/10.3390/en14185933
Firdaus, N., Ab-Samat, H., & Prasetyo, B. T. (2023). Maintenance strategies and energy
efficiency: A review. Journal of Quality in Maintenance Engineering, 29(3), 640–
665. https://doi.org/10.1108/jqme-06-2021-0046
Hadziefendic, N., Trifunovic, J., Zarev, I., Kostic, N., & Davidovic, M. (2020). The importance of
preventive thermographic inspections within periodic verifications of the quality of low-
voltage electrical installations. Machines. Technologies. Materials, 14(2), 78–
82. https://stumejournals.com/journals/mtm/2020/2/78
DOI: https://doi.org/10.71112/nchv3d08
1049 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
Himeur, Y., Ghanem, K., Alsalemi, A., Bensaali, F., & Amira, A. (2021). Artificial intelligence
based anomaly detection of energy consumption in buildings: A review, current trends
and new perspectives. Applied Energy, 287,
116601. https://doi.org/10.1016/j.apenergy.2021.116601
Hoffmann, M., Wildermuth, S., Gitzel, R., Boyaci, A., Gebhardt, J., Kaul, H., Amihai, I., Forg, B.,
Suriyah, M., Leibfried, T., Stich, V., Hicking, J., Bremer, M., Kaminski, L., Beverungen,
D., Zur-Heiden, P., & Tornede, T. (2020). Integration of novel sensors and machine
learning for predictive maintenance in medium voltage switchgear to enable the energy
and mobility revolutions. Sensors, 20(7), 2099. https://doi.org/10.3390/s20072099
Laouadi, A., Bartko, M., & Lacasse, M. A. (2020). A new methodology of evaluation of
overheating in buildings. Energy and Buildings, 226,
110360. https://doi.org/10.1016/j.enbuild.2020.110360
Ortega, M., Ivorra, E., Juan, A., Venegas, P., Martínez, J., & Alcañiz, M. (2021). MANTRA: An
effective system based on augmented reality and infrared thermography for industrial
maintenance. Applied Sciences, 11(1), 385. https://doi.org/10.3390/app11010385
Piselli, C., Balocco, C., Forastiere, S., Silei, A., Sciurpi, F., & Cotana, F. (2024). Energy
efficiency in the commercial sector. Thermodynamics fundamentals for the energy
transition. Energy Reports, 11, 4601–4621. https://doi.org/10.1016/j.egyr.2024.04.033
Rahman, A., Farrok, O., & Haque, M. (2022). Environmental impact of renewable energy source
based electrical power plants: Solar, wind, hydroelectric, biomass, geothermal, tidal,
ocean, and osmotic. Renewable and Sustainable Energy Reviews, 161,
112279. https://doi.org/10.1016/j.rser.2022.112279
Scharnhorst, L., Sloot, D., Lehmann, N., Ardone, A., & Fichtner, W. (2024). Barriers to demand
response in the commercial and industrial sectors – An empirical
DOI: https://doi.org/10.71112/nchv3d08
1050 Multidisciplinary Journal Epistemology of the Sciences | Vol. 2, Issue 2, 2025, April–June
investigation. Renewable and Sustainable Energy Reviews, 190,
114067. https://doi.org/10.1016/j.rser.2023.114067
Seabra-Paiva, L., Da Silva-Oliveira, L., Barbosa-De Alencar, D., & Oliveira-Siqueira, P. (2019).
Predictive maintenance through thermographic analysis: Case study in a Manaus
industrial pole company. International Journal for Innovation Education and Research,
7(11), 898–909. https://doi.org/10.31686/ijier.vol7.iss11.1945
Valencia-Bacilio, M., Zatizabal-Sánchez, J., Meza-Mina, L., & Chere-Quiñónez, B. (2023).
Proposal of a predictive and preventive maintenance plan in electrical substations
through the use of thermography. Sapienza: International Journal of Interdisciplinary
Studies, 4(2), e23023–e23023. https://doi.org/10.51798/sijis.v4i2.681
Venegas, P., Ivorra, E., Ortega, M., & de Ocáriz, I. (2022). Towards the automation of infrared
thermography inspections for industrial maintenance applications. Sensors, 22(2),
613. https://doi.org/10.3390/s22020613
Venegas, P., Ivorra, E., Ortega, M., Márquez, G., Martínez, J., & Sáez-De Ocáriz, I. (2020).
Development of thermographic module for predictive maintenance system of industrial
equipment. Quantitative InfraRed Thermography Conference, 15, 1–
8. https://doi.org/10.21611/qirt.2020.073
