Case Study: Advanced Condition Monitoring in Non-Stationary Operating Conditions

Hannes Gruber, Department Manager - Mechanic Development & Innovation


This presentation explores an example of advanced condition monitoring in non-stationary operating conditions, focusing on the demanding requirements of motorsport testing applications. As a foundation for this presentation, we’re focusing on the challenges in developing a highly dynamic e-motor for gearbox testing. The critical challenge lies in achieving low inertia designs for the e-motor, which, in turn, leads to elevated electrical and mechanical stresses within the structure.

Addressing these challenges necessitates the identification of various required measurements to detect potential design issues and mechanical failures at their earliest stages. To this end, a comprehensive system layout for condition monitoring is presented, including the hardware components, such as IO channels and sensors, that are integral to the monitoring process.

As a technical detail, an algorithm is presented, which offers a solution for the early detection of changes in high-frequency signals. This algorithm is a crucial part of the presented monitoring system, enhancing the ability to proactively assess the motor’s health and performance in real time. By leveraging this combination of innovative hardware and sophisticated signal processing, motorsport teams can gain a competitive advantage by identifying and addressing issues before they result in costly breakdowns, ultimately improving the reliability and efficiency of their gearbox testing operations.

Learning Takeaways:

  • Gaining insight into the challenges of condition monitoring in highly non-stationary environments
  • Providing a holistic layout for machine monitoring
  • Creating awareness of the trade between reliability and condition monitoring costs


Hannes Gruber has a background in mechanical engineering and motor racing. As a Department Manager at AVL List GmbH in Graz, he oversees the mechanical design of testing systems in the area of racing and advanced technologies.
Hannes studied mechanical engineering at the Technical University of Graz (MSc and BSc). He started his professional career at AVL List GmbH in 2011 and has since advanced through roles such as Solution Engineer and Lead Engineer, specializing in developing testbed concepts and leading research projects.
Hannes holds several patents to his name and has been making contributions to the field of condition monitoring since 2017.
His work revolves around the mechanical design of complex testbed solutions, including developing condition monitoring concepts.