Investing in new technologies to guarantee the reliability and availability of assets is not a strategy that can be left aside. Modernizing the industrial process is essential to streamline tasks and reach productive excellence.
The market for condition monitoring sensors is growing constantly. This is mainly due to their effectiveness preventing unexpected breakdowns, as well as their invaluable assistance in planning the maintenance routine, a key tool in predictive maintenance.
Interested in learning more about alternatives to monitor your machines? Then this post was meant for you! Keep reading to learn more!
The manual vibration collector is an equipment very commonly used in the industry. Its main function is to measure the general vibration for acceleration, speed and distance, being used in a wide range of machines.
The measurements have to be taken by being next to the asset and are shown in an IHM display. Afterwards, the results are stored in an internal memory with a given measurement capacity and can later be downloaded to a computer.
It works well in teams that are willing to collect data on-site, however they are more costly and are not transmitted in real time.
IoT sensors don’t depend on on-site data collection. From the moment the sensor is positioned on the equipment, the maintenance specialist does not need to worry about new collections or going to the place where the asset is located. The process is automatic and does not depend on external interferences, since it is completed 100% remotely.
To ensure your company is effectively equipped, we need to learn more about the equipment and platforms needed in order to obtain a complete online sensing.
Besides the Smart Trac sensor, the TRACTIAN solution consists of a maintenance management platform available for unlimited users. In order to use it, there’s no need for special training and the information can be consulted and managed by the maintenance specialist 24/7.
Currently, it is the most advanced method for monitoring and collecting data from a machine, using a mobile network (3G/4G) to the transmission of data. This data collection procedure via mobile network allows total independence in its implementation, i.e., it does not require special IT infrastructure to be utilized.
TRACTIAN technology is based on concepts of data analysis, machine learning and statistics to enable a thorough evaluation of the asset’s health and behavior.
A simple comparison is to provide something similar to a medical diagnostic to the asset, where we describe the characteristics that are identified during a period of time. The analysis is made with the correspondent problem related to these characteristics. For that reason, if your asset is not in normal operation, the first symptoms will be of abnormal vibrations.
The data acquired can be divided into two types:
The vibration and temperature data begin to be acquired at the moment the sensor is placed on the machine, so it’s possible to bring information about the mechanic behavior and the physical conditions of the asset.
As for the asset’s data, they are inserted in the platform by the maintenance team and for the software learning, such as: the asset model, RPM, power, limit temperature, limit downtime, bearings data, gears, fans, belts and pulleys.
After the upload, this data has to be processed. For the industries, having a software or a predictive maintenance platform is excellent since they consist of good data processing models.
When this data is combined, they provide information that will serve as a base for the metrics formation, and will later help in the creation of the diagnostics about the asset’s health.
All this data will be transformed into clear and relevant information. This process is necessary for the exploration of data, that are crucial when we talk about storage and massive data analysis, known as Big Data.
After the mapping and selection of the assets to be monitored, all you have to do it place the sensor in the right position in each machine.
Also known as “band-aid”, since it relies on a plug & play technology, the IoT sensor is extremely practical, allowing the installation to happen in up to 3 minutes.
The operation of TRACTIAN’s sensor was developed to meet the needs of maintenance teams’ reality in the best way possible. In many cases, it’s necessary to choose the best application between the cable or battery versions. They are able to measure with precision:
TRACTIAN’s sensor automatically detects:
We manage to monitor more than 30 types of assets that work in some kind of critical behaviour or defined vibration profile.
Among them, we can highlight four of the most common assets:
Unlike the traditional method, our solution is focused on the day-to-day needs of maintenance, especially because the information of the industry is on the machines, and decision-making belongs to those who are acquainted with the maintenance routine.
AmstedMaxion, the biggest manufacturer of steel wheels and casting components in Latin America, and TRACTIAN first got in touch in November 2020. Right after that, in January 2021, 12 sensors were installed in critical assets of the company.
Before the use of technology in industrial processes, unexpected breakdown were recurrent in AmstedMaxion, as Tiago Junqueira, maintenance supervisor of the company comments:
‘We had a significant increase in the amount of information about the assets with the use of sensors and the platform itself. We managed to transform all of that into knowledge, to understand the occurrences and events preceding and coming after that, so we prevented several breakdowns.’
On top of that, there was a decrease of 40% in equipment vibration and the repair of critical assets would cost around R$ 2500,00 , estimated to last one hour and a half.
AmstedMaxion’s example shows the efficiency of the use of the IoT sensors in predictive maintenance put into practice in industrial plants, optimizing the need for repairs, enhancing the reliability on the full operation of the assets and generating savings when avoiding unexpected halts in the production line.
Would you like your company to be like AmstedMaxion and adopt the market’s most comprehensive maintenance system for predictive maintenance? Contact TRACTIAN and schedule a demo.
About the author:
Santa Catarina State University graduated engineer, with more than 10 years of experience in Industry 4.0, metalworking, machine manufacturing and hydraulics. Head of Customer Success at TRACTIAN.
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