|
Wireless Sensor Networking for Predictive Maintenance
Plant managers and equipment operators need actual-status information for proper MRO intervention. Wirelessly networked sensors are ideal complements to sophisticated machinery, providing real-time signals for predictive maintenance.
Benefits to Predictive Maintenance OEMs
For OEMs and developers of predictive maintenance systems, wireless sensor networking delivers:
- New revenue predictive maintenance opportunities – The elimination of wiring opens up a new market for sensing points in machinery where wiring is impossible due to dangerous parts or inaccessible locations.
- Increased maintenance system flexibility – With the elimination of wires, sensing and monitoring points can be easily moved around to accommodate dynamic processes and environments.
- More condition data for better condition monitoring – Ease and lower cost of installation means that more sensing and monitoring points can be installed than in a wired environment, providing more condition data points to increase visibility into the system for better decision making and improved maintenance predictability.
Solutions for Predictive Maintenance
The MeshScape system is well-suited for predictive maintenance. The hardware modules are easily integrated with sensor and control devices and can be installed quickly and easily. The robust networking protocol provides redundant and scalable wireless mesh network out of the box. MeshScape delivers:
- Power efficiency for industrial operation – The MeshScape system, based on an extremely lightweight protocol, offers the most power-efficient solution on the market today. Sensor nodes can operate for years on a coin cell battery.
- High reliability for maximum uptime – MeshScape networks are the most robust wireless sensor networks offering the highest reliability of data delivery from sensor to host application in the industry. Condition monitoring data is reliably transmitted for maximum operational efficiency.
- Proven effectiveness in RF-unfriendly environments – MeshScape networks have been successfully tested and deployed in environments where heavy industrial equipment can pose potential radio-frequency obstacles.
Predictive Maintenance Applications
|
Replacing High-Touch with Wireless Automation |
Customer: |
This global instrumentation manufacturer offers a complete line of industrial automation solutions. |
Goal: |
The company wanted to add wireless capabilities to expand its product line. |
Solution: |
The first application the company wirelessly enabled was for oil refineries. In the oil refinery process, there is a cooling process that uses huge fans with motors attached to gearboxes that turn the fan blades. The gearbox is lubricated with oil but they commonly overheat and break making it the “weak link” in the system. Prevention has been decidedly low-tech; twice a shift, a human would walk over to the gearbox and touch it to make sure it hasn’t gotten too hot. The harsh industrial environment with stringent OSHA wiring requirements made this task difficult to automate until wireless sensor networking. The company used MeshScape to install sensors in the gearboxes; when the conditions exceed the threshold, a notification is sent wirelessly to fix the gearbox before it breaks. |
Benefits: |
The wireless nature of the network enables sensors to be introduced to automate the process, which is impossible with a wired solution. |
|
Eliminating Wires to Prevent Broken Pipes |
Customer: |
National utility company. |
Goal: |
This company has many older energy plants that use old steam pipes. The steam running through these huge pipes is under high pressure which causes the pipes to bend. If the pressure displaces the pipes too much, the pipes can break. |
Solution: |
The company used a MeshScape wireless sensor network to measure the displacement of the pipes. If that displacement exceeds the defined tolerance range, an alert is broadcast wirelessly and the problem can be addressed before the pipe breaks. |
Benefits: |
The cost of a broken pipe is enormous; however the ability to implement automated monitoring in this harsh environment is difficult and expensive. Wireless sensor networks makes it possible. |
|
|
|
Industrial Automation Industry Note
Read about wireless sensor networking for industrial automation applications
Industrial Automation  |
|
Reference Kits
Wireless Sensor Networking Reference Kits for Fast Prototyping
Reference Kits |
|
|
