Maintenance strategies can be categorized into three types: reactive strategies involve performing repairs and equipment replacements only after a failure occurs; preventative strategies involve performing maintenance operations periodically (the specific cycle is determined based on experience); and condition-based maintenance relies on evaluating data from condition monitoring systems using real-time diagnostics. Therefore, condition monitoring provides the fundamental conditions for intelligent prediction. These are the basis of predictive maintenance, a core issue of Industry 4.0.
Inadequate technical requirements and ongoing production processes often hinder the introduction of condition monitoring systems in later stages of existing factories. Turck provides easy-to-install sensors and suitable data transmission and monitoring solutions specifically for such projects. The QM42 vibration and temperature sensors can be directly mounted on motors and provide measurements, which can be transmitted to an HMI via wired or wireless connections, or encrypted to a mobile terminal via the Turck TCG20 cloud gateway.
Building a completely new system from scratch can present various challenges, but it also offers a significant advantage: all requirements can be considered in the early stages of the new architecture. The same applies to maintenance. Anyone planning a modern production plant or logistics center can equip machines and equipment with smart sensors, allowing for selective querying of status data for individual devices or areas. Remote inspection and efficient maintenance planning are possible using high-speed fieldbus networks and industrial Ethernet.
What should I do if the system architecture is very outdated?
How can we successfully implement the transformation without affecting the existing processes?
Does the control system need adjustment?
How can I access information from a system that is difficult to access?
Motor monitoring and renovation project
This is where customized, standalone solutions come into play, shifting from basic local monitoring tasks to wireless communication and cloud transmission. The approach: businesses can easily add equipment later to monitor machine parameters through a separate system. This way, status data can be transmitted to the customer's automation system when needed, while the existing architecture remains independent of the expanded status monitoring system.
A widespread application of this method is in motor monitoring. Motors are used to drive pumps, compressors, or exhaust fans. They typically perform high-noise, continuous tasks and are installed in hard-to-maintain locations. Regular inspections by employees cannot reliably rule out impending machine failures; on-site inspections are also very difficult. Monitoring using measuring devices is not only more reliable but also less costly. Measuring devices can measure three different parameters: vibration, temperature, and current.
Free choice:
In the design diagram of this application example, the sensor transmits temperature and vibration data wirelessly or via a connection to the TX700 HMI, which then forwards the data to the PLC or cloud wirelessly or via cable.
IP67 sensor monitors vibration and temperature.
Motors sometimes exhibit abnormalities months before actual failure. Incorrect shaft alignment, bearing sticking, or imbalanced fasteners can cause changes in vibration frequency. To detect these issues, maintenance engineers can mount the QM42 vibration and temperature sensor directly onto the motor mount. This compact sensor boasts an IP67 protection rating and can be easily secured with magnets. Based on microelectromechanical systems (MEMS), the QM42 provides high-precision two-dimensional velocity and acceleration data. The QM42 also outputs temperature values, monitoring temperatures from -40 to 105 °C to record whether the motor is overheating and where it is, thus enabling temperature trend monitoring. Motor current is also very useful. Any bearing damage or improper lubrication will result in increased mechanical resistance, requiring more current to reach the desired speed. This can be monitored using a current transformer.
The data visualization function on the TX700 HMI/PLC can even display all information directly to the user on-site.
Data transmission in wireless networks
These measurements can be used in various ways and transmitted via wired or wireless networks. In some factories, a distributed alarm system including the QM42VT2 sensor and the Turck compact TBEN-S2-2COM I/O module may suffice. With the built-in functionality of the AGREE programming environment, this fieldbus module can provide PLC functionality when necessary and send threshold exceedance information directly to indicator lights. Additionally, the TBEN module can also connect to HMI devices.
Utilizing the DX80 wireless system for wireless transmission also enables greater flexibility. For this purpose, devices such as the QM42VT1 vibration and temperature sensor are connected in series with the transmission module (node), which then sends data to the receiver (gateway). To simultaneously determine changes in current consumption, users can use a special DX80 node that provides additional transmitter signal input. If necessary, the wireless node can be battery-powered, eliminating the need for a power supply. This significantly reduces the required wiring and facilitates precise placement of the monitoring system in ideal locations.
This solution can be used in central control rooms, etc. A wireless gateway can be connected to the Turck TX700 HMI, and VisuPro software can be used to display status data from multiple machines for retrieving log files or configuring alarms. Data transmission does not need to terminate at the HMI, as it can reach other destinations via Ethernet connection: for example, an internet browser displaying or sending automated email notifications on WebVisu, and internal automation environments (PLCs, HMIs, etc.).
From the cloud to mobile devices
However, condition monitoring is not limited to physical displays and signal transmitters within the factory. The TCG20 cloud gateway can also replace the HMI, further processing data from the DX80 receiver module. This allows machine parameters to be sent to the Turck cloud via mobile network or Wi-Fi, which can be hosted without an internet connection or used as a private cloud for an internal IT center. The TCG20 also supports connection to other cloud environments in the exact same way. Advantages: Information can be accessed at any time from any connected terminal device (e.g., smartphone or tablet) and associated with SMS or email notifications. Therefore, maintenance can be performed using a separate configurable panel on the cloud portal.
in conclusion
Two common problems exist in maintenance: machine status values are often unknown; and machine status values cannot be sent to the correct recipient at critical moments. Turck has addressed these issues with its condition monitoring solutions. We now offer a complete toolkit for both scenarios, ranging from rugged sensors suitable for machine environments to visualization products on smartphones. Motor monitoring applications are a prime example: requiring minimal setup work, making them particularly suitable for existing plants. Businesses can easily retrofit condition monitoring systems and build corresponding standalone control systems.
