PAPER making! FROM THE PUBLISHERS OF PAPER TECHNOLOGY INTERNATIONAL ® FROM THE PUBLISHERS OF PAPER TEC Volume 12, Number 1, 2026
Leveraging Variable Frequency Drive Data for Nondestructive Testing and Predictive Maintenance in Industrial Systems CARL LEE TOLBERT Nondestructive testing (NDT) has a crucial role in ensuring the reliability and safety of industrial systems. However, traditional methods typically rely on external sensors, which can lead to increased costs and added complexity. The current study examined an alternative approach using variable-frequency drive (VFD) data for real-time fault detection and predictive maintenance. Most VFDs continuously monitor essential parameters such as motor speed, torque, efficiency, and power consumption, facilitating sensorless condition monitoring that helps detect early-stage motor and apparatus faults without additional hardware. To improve diagnostic capabilities, calculated metrics such as apparent power, efficiency, torque, and energy consumption can deliver more profound insights into system performance, assisting in identifying potential failure patterns. A Python-based data acquisition and visualization system was developed and implemented as an example of a potential solution, enabling centralized monitoring, anomaly detection, and historical data analysis. Future advancements in artificial intelligence and machine learning could further refine automated fault detection by utilizing historical VFD data to predict system failures accurately. By integrating VFD-based diagnostics into NDT, industries can develop scalable, cost-effective, intelligent testing and maintenance solutions that improve reliability and asset management in modern systems. Contact information: Institute for Globally Distributed Open Research and Education (IGDORE), USA. NDT 2025, 3, 7. https://doi.org/10.3390/ndt3020007 Creative Commons Attribution 4.0 International License
The Paper Industry Technical Association (PITA) is an independent organisation which operates for the general benefit of its members – both individual and corporate – dedicated to promoting and improving the technical and scientific knowledge of those working in the UK pulp and paper industry. Formed in 1960, it serves the Industry, both manufacturers and suppliers, by providing a forum for members to meet and network; it organises visits, conferences and training seminars that cover all aspects of papermaking science. It also publishes the prestigious journal Paper Technology International ® and the PITA Annual Review , both sent free to members, and a range of other technical publications which include conference proceedings and the acclaimed Essential Guide to Aqueous Coating .
Article 6 – Variable Frequency Drives
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