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Smart Condition Monitoring

Servo drive with integrated condition monitoring — without sensor

programming drive intelligence

Condition monitoring solutions allow the condition of many machines to be tracked regularly. Motor and machine wear can therefore be detected early and machine downtimes avoided. However, if this function is performed via sensors, it can quickly become very costly, depending on the type of machine and the number of motors used, such as in a textile machine.

Baumüller has developed a software solution with which the mechanisms can be monitored completely sensor-free. The smart condition monitoring software is integrated directly in the servo controller and is therefore easy to retrofit. The drive-based software solution thus increases productivity without further hardware and wiring.

How smart condition monitoring works

Smart condition monitoring is integrated directly in the Baumüller drives. The software solution uses recorded and analyzed process parameters as reference values to keep a very close eye on the mechanisms of your machines. Repeated comparative measurements taken during production identifies potential problems with motors, fans, or hydraulic pumps early in order to avoid expensive failures and to keep your machines running smoothly.

Sensor-free monitoring function in the drive

The function uses previously recorded and analyzed process parameters from the current and speed signal as reference values for monitoring the mechanical elements, such as the motor, fan, and hydraulic pump. In this way, with the help of FFT analysis and other statistically calculated indicators, deviations between the measurement and the stored reference can be identified. Among other things, the calculated data can be traced back to unbalance or faulty alignment.

If a significant deviation from the reference value is detected during operation, a warning signal can be output in good time. This allows planned maintenance for the motor and prevents further damage to or the failure of the machine. The comparison measurements can be timed to take place at fixed intervals or on demand, depending on the customer’s requirements and the application. Monitoring is based on adjustable warning and error thresholds. Machine builders can use the measurements for new business models for data-driven additional services.

smart condition monitoringThe smart condition monitoring software solution is integrated directly in the servo controller and analyzes the current and speed signal. If a significant deviation is detected, this can be used for a fault signal, thereby preventing damage

Monitoring function with sensor

In addition to the software module without sensor, a variant with sensor can also be integrated. The functional scope can thus be extended, for example, to include the evaluation of existing vibration sensors. These can be freely positioned on a mechanism. The values measured provide further information and can be additionally analyzed for a more precise fault pattern.

Intelligent drive solutions enable new business models

The smart condition monitoring software solution allows machine manufacturers to offer their customers conditioning monitoring with or without sensor link. The software is integrated directly in the servo controller via the b maXX-softdrivePLC, making it easy to retrofit. Machine manufacturers thus have new options, such as offering runtime models for additional machine functions.

b maXX-softdrivePLC

b maXX-softdrivePLC

The drive-integrated PLC runs as part of the firmware in the b maXX servo converters.

Your benefits at a glance:

  • Cost and space savings: No need for external hardware, reduction of wiring work and hardware costs
  • Reduction of standstill times: Faults and deviations are detected by continuous monitoring
  • Ready-to-use: Validated and tested software package saves development time and costs
  • Engineering as a service: We will also solve your challenge!

Readable characteristic values

The smart condition monitoring software can be integrated in different variants. One possible variant could combine the results from the speed and current measurement with a temperature energy measurement to form a signal. This can be illustrated in the visualization, for example in the form of a red/green display.

For more in-depth information, the software can provide further values, such as the historical progression, the crest factor (ratio of peak to effective value) as well as the kurtosis factor for the number of transients/outliers in the vibration signal and standard deviation. Upon a change in the current oscillations, the exact value that has deviated from the reference value is then output. The range of functions can also be extended to include the evaluation of an external acceleration sensor. This can be freely positioned on a mechanical system and the measured values can be additionally analyzed.

Smart Condition Monitoring Dashboard

The damage characteristics can also be optionally output on a clearly organized dashboard.

machine visualization

All data can be displayed compactly on the machine visualization