Use Cases Machine Condition Monitoring

Machine Condition Monitoring

Early predictions on equipment malfunctions and service maintenance can be automatically scheduled ahead of an actual part failure by installing sensors inside equipment to monitor and send reports.

Machine condition monitoring is used to determine the condition of a machine with the intent to forecast mechanical wear and failure. The predicted data provides health information about the machine and helps to predict machinery failure. The monitoring equipment tracks changes in temperature, vibration, and output of machines in order to detect an imbalance, corrosion, wear, misalignment, sediment build-up, or poorly lubricated parts.

Condition monitoring has gained importance in line with increased company focus on productivity and asset utilization.

 

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WERMA GAUDLITZ Success Story in China
WERMA GAUDLITZ Success Story in China
Gaudlitz was looking to achieve a lean management and production approach so as to improve production efficiency. Workers in the night shift were also taking a very long time to collect data.
National Grid Company
National Grid Company
NGC has a statutory duty under the Electricity Act 1989 to develop and maintain an efficient, co-ordinated and economical Transmission System for the supply of electricity. One of NGC’s statutory obligations is the requirement to maintain system frequency within the range 49.5Hz - 50.5Hz. This is achieved through the management of changing generation and/or demand. These services are automatic and can be required at any time to contain frequency deviations and recover it back to normal. To date these services have been provided by Generators, obliged to have a frequency control capability by virtue of their Grid Code connection conditions, and large industrial electricity consumers capable of interrupting firm loads for a required time. Given the limited number of production processes able to offer a firm interruptible load, NGC has been developing a frequency response service through the aggregation of fluctuating electrical loads. By combining a large number of cyclic demands, a relatively firm level of response can be derived and delivered when required.
Improved Monitoring in Industrial Manufacturing Facility
Improved Monitoring in Industrial Manufacturing Facility
When your crane is moving tons of magma-hot iron, you can’t afford an unexpected failure. McWane Ductile knew monitoring the crane motor metrics within their facility could help prevent a mechanical failure that would strand an enormous bucket of molten metal overhead. Unfortunately, their legacy wired monitoring system couldn’t work with moving objects in this extreme environment. If they could integrate wireless capabilities into their existing equipment they could extend their monitoring capabilities without starting over from scratch.
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The machine condition monitoring market was valued at USD 2.21 billion in 2017 and is expected to reach USD 3.5 billion by 2024, at a CAGR of 6.7% during the forecast period.

Source: Markets and Markets

Machine Condition Monitoring Equipment Market to Cross $3.2 Billion by 2023.

Source: P&S Intelligence

 

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What is the business value of this IoT use case and how is it measured?
Your Answer

What are the advantages of Machine Condition Monitoring?

- Increased machine availability and reliability

- Improved operating efficiency

- Improved risk management (less downtime)

- Reduced maintenance costs (better planning)

- Reduced spare parts inventories

- Improved safety

- Improved knowledge of the machine condition (safe short-term overloading of machine possible)

- Extended operational life of the machine

- Improved customer relations (less planned/unplanned downtime)

- Elimination of chronic failures (root cause analysis and redesign)

- Reduction of post-overhaul failures due to improperly performed maintenance or reassembly

 

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What business, integration, or regulatory challenges could impact deployment?
Your Answer

What are the disadvantages that must be weighed in the decision to use machine condition monitoring and fault diagnostics?

- Monitoring equipment costs (usually significant)

- Operational costs (running the program)

- Skilled personnel needed

- Strong management commitment needed

- A significant run-in time to collect machine histories and trends is usually needed

- Reduced costs are usually harder to sell to management as benefits when compared with increased profits.

 

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