A condition monitoring system consists not only of measurement technology and sensors, but also requires a central measurement data management system and platform-independent data access. With its complete solution, Delphin promises to cover all three areas comprehensively. Machine and system manufacturers should be able to offer their end customers significant added value through 'condition monitoring as a service' and thus clearly set themselves apart from the competition.
Condition monitoring - a wide-ranging area of ever-increasing importance. An increasing number of machines and systems are being equipped with measurement technology in order to keep an eye on their current status and all important operating parameters at all times. In order to save time and costs during maintenance, condition-based monitoring is increasingly being installed on smaller assets. This often happens as part of a retrofit, in which older machines that were previously not monitored are equipped accordingly. However, new machines are also increasingly being delivered ex works with pre-installed measurement technology. Manufacturers can even expand their business model by offering their end customers not only the machine or system, but also the service 'Condition Monitoring as a service'.
The three levels of a condition monitoring system
But what is actually important here? Setting up a condition monitoring system requires more than just sensors and measurement technology. On closer inspection, there are three levels that need to be considered: The data acquisition level, the central measurement data management level and the visualization and control level. The following article shows how these three levels are structured and what advantages can result from them. It also provides suggestions on how business models can be expanded to include the additional service 'condition monitoring as a service'.
Level 1: Data collection level
The basis for functioning condition monitoring is reliable data acquisition on the machine or system. In addition to selecting the right sensors, it is important to rely on a high-quality data acquisition system. First of all, it is essential to obtain precise and unadulterated measured values. This requirement can only be met by data acquisition devices with galvanically isolated analog inputs, as they can reliably prevent parasitic influences such as ground loops. Care must also be taken to ensure that the appropriate inputs are available for the sensors to be connected and that the available sampling rate meets the requirements. Attention should also be paid to the available interfaces so that the measurement technology can be easily integrated into the existing infrastructure. In addition to a fail-safe data memory that prevents data loss even if the network connection is lost, it should also be possible to pre-process the measured values in the device, for example to perform an emergency shutdown of a machine if a certain measuring channel exceeds a limit value.
The measurement technology from Delphin meets all of these requirements. The data acquisition devices have universally configurable, galvanically isolated analog inputs and can be easily set up for any measurement task. In addition, there is a genuine vibration expert that can be used for any condition monitoring task where vibration monitoring plays a role. All devices have a fail-safe, industrial-quality internal data memory and, with the software channels, offer automation options that go far beyond simply switching off a machine if a limit value is exceeded.
Level 2: Central measurement data management
Precise data acquisition is the basis of a reliable condition monitoring system. But what happens to the data, which is often distributed and initially not networked with each other? This requires a central instance that collects, synchronizes, stores and pre-processes the decentralized data and makes it available for joint visualization and analysis. With such centralized measurement data management software, high performance is particularly important in order to be able to process large volumes of data without delay. A wide range of interfaces is also important. It must not only be possible to use DAQ devices from a specific provider as data sources, but the software must be open for communication with any devices, regardless of whether they are data acquisition devices, PLCs, other field devices or intelligent sensors. The availability of central user management and comprehensive alarm options are also points that should be taken into account.
Here, too, Delphin can meet all the requirements mentioned. The Delphin Data Center is a central measurement data management software that can process up to 100 million measured values per second thanks to a specially developed binary measurement database. This eliminates performance problems right from the start. The openness of the system is ensured by communication interfaces such as OPC UA and Modbus TCP. An API interface is also available for individual data exchange. This means that the recorded measurement data can also be transferred to external applications that have been programmed using Python, for example. Global user and alarm management can also be easily implemented.
Level 3: Visualization level
What good is the most precise measurement data without good visualization? What is needed here is measurement technology software that can display measurement data as independently as possible of the location and the end device used. Often, not only a diagram display of the measurement data is required, but also a complete system visualization similar to a Scada system.
To meet these requirements, Delphin has a special platform-independent measurement technology software that can be used to display measurement data in suitable diagram types such as y(t), y(x), multi-track diagrams, bar charts and many more without any configuration effort. The special feature here is that the software works on a smartphone or tablet as well as on a desktop PC. This makes it easy to access data from anywhere in the world. The software can not only visualize measurement data, but also offers the option of creating individual dashboards to display and control processes. Many visualization elements such as analogue and digital displays, LEDs and control elements such as buttons and dials are available for this purpose. Scada-like process diagrams can thus be realized without any programming effort.
Application example: Construction machine
Too much theory? Then it's time to put it into practice: A concrete application example shows how modern condition monitoring on construction machinery has already been implemented with Delphin.
The requirement: A construction machinery manufacturer wants to offer its end customers added value by providing them with up-to-date information on the maintenance status and process parameters of their construction machinery as an additional service.
Implementation: When the end customer orders the service, a data acquisition device is installed in the relevant construction machine, which carries out vibration monitoring as well as monitoring other process parameters such as pressures and temperatures. This creates a comprehensive database for reliable condition monitoring. The Expert Vibro vibration measuring device from Delphin is used here, which enables the combined and synchronous recording of vibration measurement data up to 50 kHz and slower process data. The recorded measurement data is first stored temporarily in the device and then transmitted collectively to a central server of the manufacturer, on which a Delphin Data Center is installed. Here, the data is synchronized, stored and analysed. The current maintenance status of the construction machine is determined and appropriate recommendations for action are derived. The software now ensures that every end customer is provided with exactly the current operating data and recommendations for action that relate to their construction machinery. They can now use the ProfiSignal 20 measurement technology software to access this information regardless of their location or platform.
The customer benefit: The construction machinery manufacturer has expanded its business model to include 'condition monitoring as a service' and can generate additional revenue. The construction machinery end customer can save time and money because they are always informed about the current condition of their construction machinery and can plan maintenance work much better.
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