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  • Motor Condition Monitoring for Predictive Maintenance

    Motor Temperature Monitoring Image

    Application: Monitoring motors to prevent damage from excessive temperature

    Challenges: Hard to reach places in harsh environment

    Solution: Wireless Performance Series Gateways and Nodes

    Benefits: Reduced wiring and expandable system

    Predictive maintenance is the process of tracking the performance of crucial machine components, such as motors, in an effort to minimize downtime needed for repairs. Maintenance requirements or failing machinery is predicted by monitoring the temperature of the motor case or the bearings. The heat generated by failing motors and bearings can be detected before the devices shut down completely, minimizing facility downtime and machine damage.

    In some situations, constant monitoring of a single motor may not be required. In this case, a battery-powered FlexPower Node allows for remote condition monitoring where the equipment can be moved between multiple motors quickly.

    Remote Motor Monitoring, Minimized Downtime

    FlexPower Nodes equipped with thermocouple or RTD sensors are mounted near the motors for temperature monitoring. The sensor data is sent to a Gateway installed in a central control location. The temperature set point can be established to meet the application's requirements and then provide a discrete output from the Gateway. When predetermined temperature levels are detected, the red light of a stack light connected to a Gateway lights up, alerting personnel that maintenance is required.

    The Gateway has 6 discrete inputs and 6 discrete outputs to allow for multiple Thermocouple Nodes to interface with a single stack light indicator.

    Each of the six outputs of the Gateway is tied to a separate Node that monitors motors and provides an indication of failing components for predictive maintenance. Other elements important to motor operations, such as current draw or vibration, can be also be used for remote condition monitoring by installing the appropriate sensors and Banner SureCross Wireless products.

    Monitoring motors for proper operation with a permanently mounted or temporarily deployed wireless solution allows operators to predict potential failures. The ability to monitor motors in inconvenient locations previously not monitored allows for a more comprehensive temperature monitoring and review of equipment.

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