Electo-mechanical loads

In many repetitions of this scenario, I would estimate that the electrical folks are right at least 95% of the time.

Motors are mass-produced and standardized; they usual put out what they say they will. Mechanical designs are frequent one-of (or few-of), and they are subject to unanticipated additional loads, or failure to account for all loads in the first place.

Do we have Scientifc system of calculating motor healthiness in this scenario ?.

One live example last week - the motor was taking normal load under no load current but on load it took 6times of rated name plate current and hence was tripped continuosly. We thought that that the motor is good and worked on mechanical systems for more than 12hours but the same issue persisted.

Fianlly we took the call to replace the motor and now the problem is solved. Now my electrical guys are saying that winding would have been weak.

Interesting. Your event seems unusual. However, there might be some ways in which the motor windings might have developed an internal short circuit that would not be apparent under no load, but then draw the large overcurrent when loaded. I haven't encountered such a case before, and it seems unlikely (in the <5% group of my earlier estimate). Have further tests (Megger^® winding to winding and winding to ground, and individual winding resistance) been conducted?