Choosing the best in advance condition monitoring

Without question, the industrial internet of things has changed the way we look at condition monitoring and diagnostics. Many now consider checking analog gages and jotting down measurements on a clipboard obsolete. Manufacturers use advanced condition monitoring solutions to do the following:

• Identify issues early.
• Reduce downtime.
• Decrease maintenance costs.
• Avoid dangerous situations.
• Make more informed decisions.
• Improve labor efficiency.

All these benefits have opened the door to predictive maintenance.

Which wireless solution is best for your business? The question today is not whether you need an advanced condition monitoring solution but which type. This article explains the main differences between continuous remote monitoring and wireless route-based monitoring.

The floor of a plant has much to monitor. Image courtesy of Parker Hannifin

Wireless route-based condition monitoring. If you need a solution for short-term, on-site monitoring or diagnostics, a wireless route-based condition monitoring solution will likely give the best return on investment. The “route” refers to the asset manager’s maintenance routine, whether walking a plant floor and inspecting each machine or running diagnostics on a specific piece of equipment. Wireless sensors are installed at key points on the machines to monitor vital conditions—for example, temperature, pressure and humidity—and wirelessly transmit that information to a mobile device by using the required software or mobile app.

Wireless route-based condition monitoring alleviates these common issues:

Time. Technicians in range can wirelessly retrieve information from sensors installed on an asset. Without the wires and cables required by a traditional monitoring solution, technicians can monitor and record each measurement simultaneously, then move to the next piece of equipment. This method helps cut the time it takes to complete routes, thus potentially increasing the frequency of those routes. More daily measurements mean a more robust archive. There is also a better chance of catching the sudden spikes or drops in condition levels that often go unnoticed and lead to decreased asset performance or outright failure.

Accuracy. With one mobile device, such as a smartphone, technicians can easily and quickly monitor the digital readout and automatically record a measurement with the click of a button. Now the buildup of grease, dirt and grime on an analog gage—making it more difficult to read—is no longer an issue. Neither is the technician’s handwriting.

Record-keeping. Maintaining a digital record that can be exported and uploaded to a computer ensures that recorded measurements are no longer subject to being lost, misfiled, torn or stained by a random spill from a coffee cup. It’s also easier to analyze digital files to identify trends compared with hard copy records.