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 web-based software offers an 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 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: Our data acquisition systems come bundled with award-winning Dewesoft X data acquisition software. The 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.

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.”

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

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.

Distributed Hardware

We offer revolutionary hardware and software solution for Permanent Condition Based Monitoring (CBM) applications.

The solution is designed with application critical requirements in mind while using the latest technologies available. EtherCAT hardware architecture enables large distance distributed measurements (more than 50m node to node) with a virtually limitless number of perfectly synchronized DAQ devices connected with a single network cable, delivering power, synchronization, and data.

Fast and easy mounting of devices is facilitated by using RJ45 connectors. The single-channel solution is bringing the DAQ device very close to the sensor eliminating long analog cables and thus reducing noise pick-up and cost

DAQ hardware is a vibration and temperature measurement device consisting of:

  • SNS-ACC-1-10k-F-2m: a 1-axis 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.

  • E-ASI-2-T: data acquisition device with 2 analog input channels (with 40ks/S sampling speed per channel) for interfacing 2 MonoDAQ SNS-ACC-1-10k vibration probes and 1 digital input channel for connecting an RPM sensor (tacho).

Condition Monitoring Software

Award-winning Dewesoft X3 data acquisition software is a very powerful data recording, visualization, and analysis software with plug and play hardware and made easy to use. All hardware is bundled with Dewesoft software and offers hundreds of prepared calculation, display and analysis functions that help maintenance engineers find the machine problem and its root cause.

Some of the useful data analysis features:

  • Envelope Detection (Demodulation)

  • Rotor Balancing module

  • Order Tracking Analysis module

  • Rotational and Torsional Vibration module

  • Octave Band Analysis module


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

Envelope Detection (Demodulation)

It is a procedure used for early detection of bearing component failures. The function also includes a large database of available bearings and their frequencies. BPFO, BPFO, Cage, and Ball defect frequencies are automatically calculated by taking into consideration machine RPM and bearing model characteristics.

Learn more about Envelope detection:

Rotor Balancing module

Your rotor unbalance creates high noise and results in earlier machine defects. Detecting unbalance and performing balancing was never so intuitive and easy as with MonoDAQ Hardware and DEWESoft balancing module.

Balancing module core features are:

  • Single or dual-plane balancing on-site
  • Simple step-by-step procedure
  • Rich visualization
  • Weight splitting
  • Storage of influence vectors


​​​​​​​Learn more about Roto Balancing module:

Order Tracking Analysis

It is a true ECG for machines. It is a perfect tool to determine the operating condition of the rotating machines (resonances, stable operation points, determining the cause of vibrations). Order tracking analysis enables you to analyze the performance of each part of the machine individually.

Learn more about order tracking analysis module:

Rotational and Torsional vibration

Torsional vibrations are quite often a source of issues and faults on the long shafts. Rotational and torsional vibration module is a tool to troubleshoot such issues in condition monitoring applications.

Rotational and Torsional vibration core features:

  • Easy sensor setup
  • Access to all data
  • Advanced math
  • Order tracking integration


​​​​​​​Learn more about torsional vibration analysis module:

Octave Band Analysis

Due to its logarithmic frequency axis, octave analysis is an indispensable tool for sound measurement as well as predictive monitoring. Dewesoft octave analysis solution meets all of the IEC and ANSI Class I specifications for octave filters.

Octave Band Analysis core features:

  • True octave analysis

  • Synthesized analysis

  • Resolution up to 1/24 octave

  • Frequency sound weighting

  • Frequency averaging


​​​​​​​Learn more about the octave band analysis module:

Historian Time Series Database

For the long term measurement and data storage, we provide the Historian service. Historian is a time-series database for long term data storage. The database can be either located locally, on the remote server or in the cloud. 

Historian provides several useful features for your historic data:

  • Raw and reduced data: while raw data is always stored on the measurement unit for an in-depth analysis, the Historian takes the role of long-term reduced data storage into the cloud database.
  • Data safety and retransmit: if connection between the measurement hardware and the database is lost, the data is safely stored locally on the measurement unit and then retransmitted to the database when the connection is available.
  • Trending and Analysis: Historical data can always be recalled and loaded from the Historian database and used for trend analysis as well as for in-depth analysis and root cause identification.

Industry 4.0 (IIoT) Connectivity With OPC UA

Cloud Software

Cloud Software infrastructure is available for graphical representation of the machine state. Visualization and monitoring technology of long-term trends is available. On top of that thresholds and alarms are available to be used in combination with e-mail or SMS notifications.

The user interface can be easily customized according to customer's requirements. The data is streamed from the Dewesoft DAQ software running on the local PC over OPC into a database. The database can run on a local server or in the cloud.

SCADA

Data transfer from Dewesoft to SCADA is straightforward by using the Dewesoft OPC UA Server or Client modules. In this case, Dewesoft software acts as a SCADA server or client, depending on the requirements set by the customer.

Industrial communication protocols

Several industrial interfaces and protocols are open either to serve or read data. OPC UA, Siemens S7, MODBUS, Serial communication, and EtherCAT/Ethernet communication protocols are supported within Dewesoft as optional upgrades.

Condition Monitoring Applications

Dewesoft CBM solution is perfect for several applications in:

  • Pulp & Paper: conveyor belts, chippers, chip classifiers, blowers, screw conveyors, refiners, pressure screens, agitators, nip monitoring, felt rollers, etc.
  • Iron & Steel: conveyor belts, raw material handling machines, ship unloaders, stack reclaimers, continuous casters, cranes, rolling mills, annealing machinery, galvanization plants, and also pumps, fans, and gearboxes, etc.
  • Automotive: air handling units, pumps, etc. Presses and transfer presses, where the formation of the plate is done is another important section of the industry.
  • Power generation
  • Oil and Gas

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!

Matej Kranjc, Managing Director, SCIMEAS Australia:  
MonoDAQ is the only DAQ company that offers a single channel robust DAQ system accompanied by DAQ software with virtually limitless possibilities. After a thorough investigation, the customer decided to equip all of its CNC machines with the Dewesoft CBM solution. After using the solution for one year the benefits of the MonoDAQ system are very clear. They reduced maintenance costs by 55% and increased profits by 3%! Dewesoft, thank you for your support and I wish you good luck!

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.

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