How does TRACTIAN’s online monitoring sensor work?

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.

Check out our complete guide to Maintenance Planning and Control (MPC)

Interested in learning more about alternatives to monitor your machines? Then this post was meant for you! Keep reading to learn more!

Manual sensor vs IoT sensor

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.

Offline and Online Predictive Maintenance: Which One You Should Choose?

How does the online sensing work?

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.

1. Data processing

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.

2. IoT sensor for data collection

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.

TRACTIAN was named one of the fastest-growing SaaS companies in the world

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:

  • Vibration data, temperature data and hour meter;
  • Asset’s data.

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.

3. Cloud connectivity

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.

TRACTIAN is ranked as one of the 3 best maintenance softwares in the world

How is the installation of the sensor? 

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.

What are the advantages of our technology?

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:

  • Temperature, ranging from -10 to 80 (ºC)
  • Asset’s hour meter

TRACTIAN’s sensor automatically detects:

  • Changes in setup, processed material or speed;
  • Wear and tear;
  • Imbalance;
  • Misalignment;
  • Mechanic looseness;
  • Anomalous peaks;
  • Gears;
  • Bearing failures;
  • Lack of lubrication;
  • Deposition;
  • Filter’s wear and tear;
  • Cavitation.

Which assets are compatible with the sensor?

We manage to monitor more than 30 types of assets that work in some kind of critical behaviour or defined vibration profile.

Tractian: which assets does the sensor monitor?

Among them, we can highlight four of the most common assets:

  • Compressor (volumetric, piston, screw and scroll);
  • Electric motor (direct and alternate current);
  • Fan (axial, centrifugal or radial);
  • Motorised pumps (peripheral and centrifugal).

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.

Sensing in practice

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.

Check out the entire Sucess Case between AmstedMaxion and TRACTIAN

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.

Insight generated by the Tractian Platform

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.


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About the author:

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Pedro Piovesan

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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