Smart sensors are an ongoing feature in the pump industry. An existing player is expanding its offerings to offer complete monitoring and data analysis capabilities.
WEG has already introduced two wireless smart sensors that can be used with a simple smartphone interface or a gateway. It is well known that monitoring critical equipment’s performance through condition monitoring makes it possible to detect early changes in equipment, providing end-users with enough time to take the necessary steps to avoid unexpected downtime.
But what has changed significantly in recent times is the development of smaller, smarter, cheaper sensors and inexpensive support systems that can provide more practical visibility to the number of machine data points with comparably little investment.
Top factors for real outcomes
WEG has considerable experience in understanding how to achieve real outcomes for maintenance and reliability teams. It ultimately comes down to several essential factors.
Condition monitoring must be easy to install and set up, reducing set-up time and labour costs. The systems need to integrate with a range of existing assets and follow site practices, further minimising onboarding and maintenance problems. Data loggers must be robust and account for dust and water ingress with a suitable IP rating.
The data itself must be secure, and end-users must have strict controls over it. The reports that come out of the collected information need to be understood, from basic monitoring to highly complex diagnostics. That data needs to be broken down into its constituent parts to ensure maximum visibility.
It’s also essential to understand the financial aspect of such a program. Companies may baulk at the initial upfront cost, but such assessments need to take on board the benefits of improving safety, productivity, and finances.
How WEG plays a role
Considering these factors, WEG is introducing an additional patented technology to its wireless condition monitoring suite for use with the WEGscan.
In a system where the sensors are already performing periodic measurements of vibration, temperature, power consumption, motor efficiency, bearing health and running hours, WEGsync technology combines the synchronous vibration measurement of multiple sensors for the asset’s phase and structural deformation analysis.
Simply put, the data from multiple sensors is synchronised and analysed, allowing the specialist to concentrate on the immediate outcomes rather than the measurements themselves. This saves time, and the overall monitoring process becomes less expensive.
Flexibility in data capture
The sensors can be easily fitted to a wide variety of machines and fixed locations if necessary, becoming a strategic resource for any maintenance or engineering team measuring temperature, vibration, functional hours, and real-time operations. They can also be used for machine health trending or operational deflection shape information as required.
In addition, the WEG Motion Fleet Management (MFM) platform offers access to modules such as “motor specialist” and “exchange”, which provide access to advanced algorithms for more complex failure and energy consumption analysis and any data integration with the customer’s systems.
The intended outcomes are plant productivity, efficiency, planning, and profitability. From the basics of alarms and data viewing from a smartphone app to analysis and data sharing through the WEG MFM platform, WEGscan can be adapted to any site’s needs and practices.
Image: WEG Australia
