Machine Condition Monitoring and Predictive Maintenance

Space-grade measurement technology brought into machine condition-based monitoring. Accurate, highly reliable, easy to use and cost-effective real-time condition monitoring solution. 

Our condition-based monitoring solution is ideal for any kind of rotating machinery such as electric motors, gearboxes, pumps, etc.

Vibrations
Vibrations
Strain / Stress
Strain / Stress
Force
Force
Temperature
Temperature
RPM
RPM
Quarter Bridge
Quarter Bridge
Half Bridge
Half Bridge
Full Bridge
Full Bridge
Thermocouple
Thermocouple
RTD
RTD
Counter/Encoder
Counter/Encoder
Video
Video
High-speed video
High-speed video
Thermal video
Thermal video
EtherCAT
EtherCAT
Ethernet
Ethernet
OPC UA
OPC UA

Main Features

 

  • READY TO USE HIGH-LEVEL WEB-BASED SOFTWARE: The Dewesoft Machine Condition Monitoring software includes a web-based overview of the machinery state, indispensable for quick decision making..
  • IN-DEPTH MACHINE CONDITION ANALYSIS FEATURES: Thousands of software features relevant to PdM experts are available including FFT-analyzer, time-domain analysis, orbit plot, order tracking, waterfall diagram, trend statistics, enveloping, bearing fault detection.
  • HISTORIAN TIME-SERIES DATABASE: Historical data can be permanently stored in a Historian database on a local or cloud server and can be used for trends as well as for later in-depth analysis and root cause identification.
  • CONNECTIVITY WITH OPC UA: Data can be integrated into any 3rd party control system using the OPC UA protocol.
  • DATA ACCESS FROM ANYWHERE: Data can be accessed from the client’s local computer, mobile phone devices, control system or remotely via a pre-configured web browser application.
  • UNLIMITED INPUT CHANNELS: Our DAQ systems offer virtually unlimited input channel configurations and our DAQ software can perform machine condition monitoring analysis on any or all of them at the same time.
  • TOTALLY DISTRIBUTED SYSTEM: Dewesoft DAQ devices are designed to be distributed under any condition. EtherCAT technology allows devices to be placed near the sensors and connected with a single cable for power, data, and synchronization. The cable can span up to 100m between DAQ nodes or virtually unlimited using EtherCAT to fiber optic converters.
  • ANY SENSOR: input amplifiers offer support for any velocity, accelerometer, temperature, pressure and any other types of sensors needed to detect rotating machinery issues.
  • LIFETIME FREE SOFTWARE UPGRADES AND SUPPORT: The machine condition monitoring software package is always evolving and new features are being added. We offer lifetime FREE software upgrades and technical support to all our users.

 

Condition Based Monitoring (CBM)

Machine condition monitoring (or condition-based monitoring - CBM) is the process of monitoring condition in machinery while in operation (vibration, temperature, etc.), in order to identify a significant change which is indicative of a developing fault or malfunction. It is a major component of predictive maintenance.

Dewesoft is a leading provider of high-end data acquisition systems (DAQ), DAQ software covering test and measurement applications in different industries. We also offer low-cost, high performance, totally distributed and easy to use machine condition monitoring systems for condition-based monitoring.

The solution suits applications such as permanent condition-monitoring of gearboxes, fans, motors, blowers and any other rotating machinery in automotive, mining, pulp, paper, iron, steel, chemical, cement, oil and gas, facility management and power generation.

This cost-effective solution enables production facility owners to start permanent monitoring of critical equipment with high ROI. Ultimately, it helps reducing production downtime, lowering maintenance and repair costs and increasing company profitability.

Condition Based Monitoring (CBM)

Why Is Permanent Monitoring Needed?

Using condition monitoring techniques is the only way to understand the condition of your machines in detail and to be able to perform the right maintenance at the right time.

Example: imagine how vulnerable would people be without the sensing ability?

US Department of Energy: The efficiencies of mechanical equipment, in general, can be increased typically 10 to 15 percent by permanent condition monitoring and scheduled maintenance.”

Why Is Permanent Monitoring Needed?

What parameters can we measure and observe?

  • Temperature monitoring
  • Vibration monitoring
  • Strain monitoring
  • Pressure monitoring
  • Rotational speed monitoring
  • Force monitoring
     

What faults can we detect?

  • Bearing faults
  • Overheating
  • Shaft un-balance
  • Detached mounting
  • Gear-tooth failure
  • Load misalignment
  • Stator excentricity
  • Other machine catastrophic failures
What parameters can we measure and observe?

Why Dewesoft?

We helped many companies to:

  • Drop repair costs by 32% on average
  • Reduce maintenance cost by 52% on average
  • Increase plant life
  • Increase revenue by 17% on average
  • Reduce spares inventories by 26% on average
  • Increase personnel safety
  • Cost savings in general


How Do We Help?

Every Condition Based Monitoring project flows through different phases in which strategic choices are made. If made in the right way, it will bring you the desired results.

Dewesoft system integrator companies will guide you through several critical stages delivering you a fully customized Turn-Key Condition Based Monitoring solution ensuring improved safety, availability and efficiency of your production plant.

Why Dewesoft?

Distributed Hardware

The latest Machine Condition Monitoring solution introduced on the market is the Dewesoft IOLITEd-2xASI, a device with two analog sensor interface channels and one tacho specifically designed to work with Dewesoft ASI-1xVIB-50g, a 10 kHz vibration, and temperature sensor. 

  • IOLITEd-2xASI: data acquisition device with 2 analog input channels (with 40 kS/s sampling speed per channel) for interfacing 2 Dewesoft ASI-1xVIB-50g vibration probes and 1 digital input channel for connecting an RPM sensor (tacho).
    Download datasheet
  • ASI-1xVIB-50g: a 1-axis high bandwidth (10 kHz) and low noise vibration sensor probe which also includes a temperature sensor and 3-axial low-speed accelerometer for orientation identification.
    Download datasheet


Benefits: The solution is designed for applications where distributed measurements of limitless numbers of perfectly synchronized vibration and temperature measurements are of the essence and where cost plays a significant role. Fast and easy mounting of devices is facilitated by using RJ45 connectors. The solution is bringing the DAQ device very close to the sensor eliminating long analog cables and thus reducing noise pick-up and cost.
 

IOLITE Data Acquisition Systems

IOLITEr and IOLITEs are multi-channel general data acquisition devices with a wide range of input types with 24-bit resolution and 20 kS/s sampling speed. Available modules for measurement are:

  • voltage,
  • current,
  • strain gage,
  • vibration (IEPE),
  • temperature - universal thermocouple and RTD,
  • digital I/O and more.


EtherCAT communication ensures perfect synchronization between devices.

IOLITE Benefits

IOLITEr and IOLITEs are designed for applications where a larger amount of channels is needed at the same spot while being part of a wider EtherCAT measurement network. IOLITEr and IOLITEs also feature a secondary EtherCAT bus that can be used for parallel real-time data output to a 3rd party control & protection system.

KRYPTON Rugged Data Acquisition Systems

KRYPTON EtherCAT DAQ devices feature 3-8 measurement inputs in a rugged, waterproof and high-temperature range package for harsh environments. Devices can be daisy-chained between each other using a single rugged cable with Lemo connectors for power, data, and synchronization.

Benefits: KRYPTON devices are meant to be used in the harshest environment while fitting into the same EtherCAT chain with IOLITE devices. 

See the KRYPTON rugged DAQ video.

Distributed Hardware
Distributed Hardware
Distributed Hardware

Condition Monitoring Software

The Dewesoft machine condition monitoring software is unique on the market. It combines PC Client software with in-depth machine condition analysis features, relevant for PdM expert engineers, a high-level Web-based software layer with an overview of the machinery state, appropriate for quick decision making and Historian time-series database for permanent storage of the data.

Dewesoft machine condition monitoring software user interface is translated into all major languages - English, Spanish, Portuguese, Chinese, Japanese, Korean, German, Italian, French, Russian and others.

Learn more about Dewesoft machine condition monitoring software.

Condition Monitoring Software

System architecture

Dewesoft Data Acquisition systems, with its wide range of analog and digital inputs, offer support for almost any kind of 3rd party sensor. Digital and analog output devices provide the ability to drive actuators or switches. 

All EtherCAT compatible devices (IOLITE, KRYPTON) can be connected into the same network giving the possibility to build a virtually unlimited channel chain by using a single cable delivering power, synchronization, and data. The whole EtherCAT chain is synchronized to 1us no matter the distance. Node-node distances can be up to 100m

All the raw data from data acquisition devices are collected and processed by measurement units running the Dewesoft X3 Machine Condition Monitoring software. Processed data is sent over the TCP/IP network to the factory server. Data can be accessed and viewed on the client PC or stored in the time series database (Historian) and served to SCADA systems or Cloud Software using standard interfaces such as OPC/UA or XCP to truly support Industry 4.0 applications

System architecture

Condition Monitoring Applications

Dewesoft CBM solution is perfect for several applications in:

  • Pulp & Paper: Blowers, conveyor belts, chippers, chip classifiers, refiners, pressure screens, screw conveyors, agitators, nip monitoring, felt rollers, etc.
  • Iron & Steel: Raw material handling machines, conveyor belts, ship unloaders, galvanization plants, stack reclaimers, continuous casters, cranes, rolling mills, annealing machinery and also pumps, fans, and gearboxes, etc.
  • Automotive: Wind Tunnels, Air handling units and pumps in paint shops as well as presses and transfer presses, etc.
  • Cement: Crushers, gearboxes, conveyor belts, separators, fans, raw mills, ball mills, elevators, and blowers.
  • Industrial plant and facilities: Gearboxes, UPS, AC, electric motors, fans, pumps.
Condition Monitoring Applications

Customer Testimonials

Sandro Berchiolli, CEO, ISE Srl: 
Dewesoft's solution modularity and flexibility have given us more opportunities and improved our CBM applications. Compact, easy to install and really powerful.

Mauricio Fachinetti, Managing Director, TOPFIBRA:  
I was impressed by the professional approach of Dewesoft personnel. After a thorough investigation, they installed their permanent CBM solution that not only works but it saves a lot of money and time at my customers. On average they saved more than 40% on repair costs and increased the revenue by 15%. Amazing performance!

Fadi Lama, YLE GmbH:
Dewesoft product line is a perfect fit for high fidelity, distributed CBM monitoring applications. What I really liked about Dewesoft, on top of their product line, is their very professional and quick response support team.

Customer Testimonials

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