Machine Condition Monitoring and Predictive Maintenance

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.

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

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.

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. 

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.