Machine Condition Monitoring Service Provider
When the IoT capabilities are implemented in the Industrial and Manufacturing space, it becomes Industrial IoT(IIoT) ,also known as Industry 4.0 in which billions of industrial devices or machines that are filled with sensors,connected to wireless networks, gathering and sharing data. The sensors and high-bandwidth wireless networks can be connected up,given a level of digital intelligence which allows them to monitored ,tracked and automate or even can share data on the status and communicate with other devices. All of this data can be collected and analysed to make business processes more efficient.
This technology collaborates different technologies like machine learning, big data,sensor data, M2M communication and automation that have existed in the industrial backdrop for many years. Condition monitoring is a vital element of predictive maintenance, and it plays a pivotal role in assuring the health of machinery and equipment that provides them with continuous efficiency. Condition monitoring technique has travelled with the transformation of the industrial revolution and got better over the years. The era of industry 4.0 is all set to enhance the condition monitoring technique this time with advanced technologies like IoT sensors and big data analytics.
Condition Monitoring
Services for CNC Machines
When the IoT capabilities are implemented in the Industrial and Manufacturing space, it becomes Industrial IoT(IIoT) ,also known as Industry 4.0 in which billions of industrial devices or machines that are filled with sensors,connected to wireless networks, gathering and sharing data. The sensors and high-bandwidth wireless networks can be connected up,given a level of digital intelligence which allows them to monitored ,tracked and automate or even can share data on the status and communicate with other devices. All of this data can be collected and analysed to make business processes more efficient.
Condition monitoring is a vital element of predictive maintenance, and it plays a pivotal role in assuring the health of machinery and equipment that provides them with continuous efficiency. Condition monitoring technique has travelled with the transformation of the industrial revolution and got better over the years. The era of industry 4.0 is all set to enhance the condition monitoring technique this time with advanced technologies like IoT sensors and big data analytics.
Why Industries Need Condition Monitoring?
Condition Assessment
Here comes,Condition Monitoring that makes the Condition Assessment remotely which does not need any physical access to the machine which makes work easier , save time. With Condition Monitoring, we take set of granular data that includes sensor data from the machine,previous inspections,other machine of the same type,location and condition of the plant and historical trends.
This not only defines the machine’s status but also predicts future issues and when they are likely to occur,including when the part will need replacement. Manufactures can monitor the condition of machines in real time to predict malfunctions and schedule service maintenance ahead of an actual failure.
We are seamless Condition Monitoring Service Provider in Chennai, India who ensures the predictive maintenance process is carried out without any flaw and paves the way towards non-stoppable machinery operations.
Right now IIoT opens plenty of opportunities in,
- Condition Monitoring(CM)
- Predictive Maintenance
- Asset Tracking
- Inventory management
Condition Monitoring Improving Business
- Around 53% of maintenance costs get incurred due to hidden internal faults, and condition monitoring is tailor-made to avoid these unnecessary situations.
- Low-quality tools and machines result in 49 hours of productivity loss in a year which is found to be a great setback, implementing condition monitoring, will help manufacturers to overcome this situation.
- Stereotypical maintenance tasks scheduled regularly without monitoring the exact condition of a machine, this scenario will be completely avoided with condition monitoring as it prioritizes the scheduling of a machine according to its healthy condition.
- Fixing machinery issues instead of replacing them would bring in a 40% save in their spending, condition monitoring makes it happen for the manufacturing industry in fixing the defects faced by machines.
- Condition monitoring helps manufacturers to track the exact performance of their machineries and create a detailed report analyzing their contribution towards the growth in productivity.
- The condition monitoring services we deliver for preventive maintenance helps your manufacturing unit to operate without any unexpected shutdown and also contribute towards high productivity.
Condition Monitoring Sensors
we deliver
Temperature Sensors
To avoid these circumstances, we have to monitor the temperature of the coolant. Here we use the Temperature Sensors to measure the amount of heat that is being liberated from the machine , allowing us to sense or detect any change in physical temperature to that temperature producing either an analogue or digital signal output. It is placed between the spindle with the tool and the Chuck which holds down the object to measure the operating temperature and also monitors the coolant temperature, which is also an important factor to note.
By adopting our Condition Monitoring Service you can certainly maintain the exact temperature of the workpiece that eventually paves the way towards hurdless working of the entire system.
Speed sensor
Normally the speed of the CNC machine is pre-programmed, so usually, we don’t care about that factor. But sometimes errors could arise in the controller system and as a result of which the spindle runs out in its maximum speed and could damage the object and the tool we use. So to Rectify this issue we have come up with the idea to use the Speed sensor to find out the spindle speed.
It is placed over the spindle and we can use the Encoder and Decoder’s to measure the speed of the spindle. As a result of which when the encoder detects the decoder it produces some intensity of potential difference which enables to measure the speed of the Spindle. We deliver excellent Condition Monitoring Services for CNC Machines in Chennai, India that accurately measures the speed range and ensures it provides useful contribution for the running of CNC machines.
Vibration sensors
The vibration of the machine could be monitored by using the Vibration sensors and also it would be used for measuring, displaying, and analyzing linear velocity, displacement and proximity, or acceleration in the CNC Machine. Therefore, vibration analysis is used as a tool to determine equipment condition as well as the specific location and type of problems.
It is particularly placed in the machine to find the Vibrations in the Ball Bearing assembly, near the Spindle and the tool. The Condition Monitoring Services delivered for CNC machines deeply inspects the vibration factor and contribute towards prolonged life of the CNC machine.
Noise Sensor
Due to the incorrect positioning of the tool and the spindle would cause vibrations and which may lead to producing Noise, but the thing is that you wouldn’t be able to sense the small intensity of those sounds. So we use the Noise Sensor to Detect the Noise which arises from the CNC Machine. It recognizes any change or a small unusual sound in the machine and would intimate us.
We are the best Condition monitoring service provider in Chennai, India who provides perfect assistance for your noise sensor fixed in CNC machines to detect minute sounds and predict the damage which will happen in future.
Pneumatic Pressure Sensor
Improper flow of coolant cause distortion on the surface of the work piece and sometimes causes tool breakage due to overheating. Pressure variation could cause improper flow of coolant on the work piece. Maintaining a proper flow of the coolant could be achieved by monitoring the coolant flow with pneumatic pressure sensor.
Integrating and monitoring a pneumatic pressure sensor on the output tube from the coolant and air junction could be useful in monitoring the current flow pressure as well as maintaining a proper output pressure by regulating the pump action. The seamless Condition Monitoring services we provide for CNC machines helps to keep a check on the pressure of the workpiece and avoids unnecessary tool breakage or distortion.
Level Sensor
Maintaining a proper level of coolant is a must to avoid pump running in idle condition. Maintaining proper coolant level could also avoid variations in the pressure coming out of the coolant nozzle. The level sensor is used to identify the level of coolant in the tank. Incorporating a level sensor could intimate once the coolant level goes below the required level before the notice of malfunction.
This sensor is fixed in the coolant tank and can alert when the coolant level in the tank goes low. This could avoid overheating of tool and breakage. As the intimation goes to the head office directly, things are processed much faster without any demand in the supplies. We maintain high quality in Condition monitoring for CNC machines that helps the level sensor to work flawlessly and maintain proper coolant level.
Condition Monitoring Implementation
CM Techniques
- Vibration analysis
- Lubricant analysis
- Temperature analysis
- Acoustic emission
- Cracking Detection
- Spalling Detection
- Assembly Misalignment
- Model-based voltage and current system
Oil and Gas
- Pressure Vessel Monitoring
- Drilling Equipment Monitoring
- Storage Tank Monitoring
- Pipeline Monitoring
Electricity
- Steam-turbine monitoring
- Gas turbine monitoring
- Pulse-Shock Sensor Monitoring
- Gearbox Bearings
