In the face of advancing automation, condition monitoring is becoming increasingly important in industry. More and more machines and systems are being equipped with measurement technology that allows all relevant measurement data and parameters to be continuously monitored and analyzed. This approach also offers advantages for smaller systems, as it saves time and costs during maintenance and helps to avoid malfunctions and machine downtimes. Delphin presents the architecture required to successfully monitor machine conditions and the benefits of condition-based monitoring for companies.
It is not only new machines that are increasingly being equipped with pre-installed measurement technology ex works. Older, previously unmonitored systems are also increasingly being retrofitted. Some manufacturers have even adapted their business model and offer their customers the condition monitoring service in addition to the product
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Three key levels for an effective condition monitoring system
Sensors and measurement technology alone are not enough for a functioning monitoring system. There are three levels to condition monitoring: the data acquisition level, the central measurement data management and the visualization level. The following sections provide an overview of the architecture required to successfully monitor machine conditions and the benefits of condition-based monitoring for companies. It also shows how the condition monitoring service can be integrated into existing corporate strategies.
Precise data acquisition as the basis for condition monitoring
The basis for a functioning condition monitoring system is the reliable recording of all important machine or system data. The selection of suitable sensors is just as important as a high-quality data acquisition system. Precise, unadulterated measured values are of crucial importance. This requires data acquisition devices with galvanically isolated analog inputs that can prevent signal distortion caused by ground loops and interference due to potential differences. In addition, suitable inputs for the sensors to be connected and a sampling rate that meets the requirements must be provided.
To ensure smooth integration of the measurement technology into the existing infrastructure, it is important to keep an eye on the available interfaces when selecting the devices. A fail-safe data memory that prevents data loss even in the event of a network fault can offer advantages, as can the option of pre-processing the measured values directly in the device. The latter enables the emergency shutdown of a machine or system if a measured or characteristic value exceeds a defined limit value.
The data acquisition devices from Delphin are equipped with universally configurable, galvanically isolated analog inputs and can be set up for any measurement task. In addition, Expert Vibro is a vibration measuring device for vibration data acquisition and vibration analysis that can be used for any condition monitoring task in which vibration monitoring is relevant. All devices are equipped with a fail-safe, industrial-quality data memory and offer analysis and automation functions via so-called software channels, which can be used to easily switch off machines and systems if limit values are exceeded.
Central measurement data management - collect and analyze data intelligently
Precise measured values are the basic prerequisite for effective condition monitoring. However, in order for them to fulfil their purpose, the data, which is often collected at different locations and initially not networked, must first be "collected", synchronized, stored, pre-processed and made available for joint visualization and analysis. This is the task of central measurement data management.
This instance is implemented using measurement data management software, which must offer high performance in order to be able to process large volumes of data efficiently and without delay. It is also important to have a wide range of interfaces that allow any other devices to be used as data sources in addition to data acquisition devices from a specific provider - regardless of whether they are data acquisition devices, programmable logic controllers, intelligent sensors or other field devices. Centralized user management and comprehensive alarm options can further increase the potential of condition monitoring systems and are also becoming increasingly important due to the significant increase in data protection and cyber security requirements.
The Delphin Data Center (DDC) from Delphin can process up to 100 million data records per second thanks to a binary measurement database. This avoids performance problems right from the start. Modern communication interfaces such as OPC UA and Modbus TCP ensure the openness of the system. In addition, an API interface enables individual data exchange. The recorded measurement data can therefore also be made available to external applications that have been programmed using Python, for example. Global user and alarm management can also be implemented with the DDC as the central measurement data management software.
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