Condition Monitoring with DATAEAGLE
Our IoT-Ready-to-use approach
Condition monitoring (CM) for machines and plants offers many industries considerable possibilities for production and quality assurance. More and more sensors collect critical operating data, which can be used to keep machines and plants healthy for longer. A prerequisite, however, is that the sensor data reach the point where a critical assessment can be made quickly and reliably and appropriate measures can be initiated.
In order to enable the customer to implement this quickly, Schildknecht AG follows the IoT-ready-to-use approach: a ready-to-use system for condition monitoring consisting of a small multi-sensor for harsh industrial environments, a global IoT-Gateway (DATAEAGLE 2730) with integrated eSIM-card and a cloud dashboard (DATAEAGLE portal). It is suitable for new and existing installations.
The robust CISS sensor from Bosch can be mounted directly onto the engine or the machine and transmits the data via Bluetooth Low Energy to the central IoT Gateway DATAEAGLE 2730.There, the values from up to 8 sensors can be received simultaneously. These are then pre-processed and transferred to a cloud portal at intervals. The data is then stored in the DATAEAGLE Portal in order to display the sensor values and analyse long-term effects. The transmission interval of the sensor values to the cloud depends on the operating mode and is optionally also alarm-controlled.
Condition Monitoring – First Steps and Installation
First steps for introducing condition monitoring
A good way to get started is to focus on the weak spots of your factory. Ask yourself these questions:
• What are the weakest parts of my production setup?
• Where do breakdowns occur most frequently?
• Where do failures have financial consequences?
• Where do breakdowns have widespread effects, e.g. because several production lines are blocked as a result?
Very likely you’ll be able to point out specific pumps, motors, or other equipment that constitute critical weaknesses in need of constant monitoring. This is the place to start. The next step is to determine what you want to measure. The most common values are temperature, vibrations and noise level. However, the IoT Ready-To-Use system enables you to measure much more if necessary. Its CISS multi-sensor for harsh environments contains 8 sensors:
• accelerometer
• gyroscope
• magnetometer
• digital light sensor
• pressure sensor
• microphone
• thermometer
• humidity sensor
This versatility allows you to experiment and to adjust the setup along the way until you have found the best parameters to monitor on your machines and equipment. This adjustment can be done on our cloud portal, otherwise known as DATAEAGLE Portal. You can even install multiple sensors to your machine at different points and connect them to the gateway, DATAEAGLE 2730, to get a better and accurate understanding of the health of your machine.
Start with monitoring one application
To get started, it is important to focus on one application or machine. Don’t think too much about integration or turning this into a multi-functional system. Save that for later. The initial phase is all about focusing and building a strong case around one single application. This also lets you control costs and installation time.
From this point on you can adjust and expand your condition monitoring solution easily, as the Schildknecht wireless concept with decentralized sensors and central gateways gives you the flexibility to change your setup along the way.
For instance, you might have a number of older machines in your factory, with all the problems that go with them in regards to repair and spare parts. It would make good sense to monitor them closely to ensure maximum uptime and to extend their life span. A non-invasive system like IoT Ready-To-Use ensures easy retrofitting with the least possible installation efforts and disruption to production.
Or you can work towards the convergence of your IT and OT infrastructures. As IT and OT move closer together you might want to get a simultaneous overview of both worlds. For this, Schildknecht is partnering with PAESSLER, and data from the Schildknecht system can be easily integrated into the PAESSLER PRTG Monitor.
Install the condition monitoring system
Getting a condition monitoring system up and running doesn’t have to be complicated and time consuming. We have designed our system explicitly with ease-of-use and flexibility in mind.
For instance, no integration is needed, and its multi-sensor has magnets for easy installation. Also, to avoid the hassle of installing extra wiring, the system’s gateway uses radio communication to send monitoring data to a cloud portal.
You can mount the multi-sensor directly on the engine or machine. It transmits measurement data via Bluetooth Low Energy to the DATAEAGLE 2730 IoT gateway, which is able to receive data from up to 8 sensors simultaneously. The gateway then pre-processes the data and transfers it via wireless 3G/4G to the cloud, where it is stored and ready to be visualized and analysed via the DATAEAGLE Portal.
The DATAEAGLE Cloud Portal provides a ready-to-use dashboard to get an overview of the data coming in from the sensors. At this point you can analyse the data, with support by Schildknecht’s consultants as needed (free of charge). Depending on the use case, you can set different transmission intervals of the sensor values to the cloud, or you can set alarms for individual sensors.
Install – Condition Monitoring System
Webinar: CONDITION MONITORING SYSTEM
OUR CONDITION MONITORING SYSTEMS AT A GLANCE
DATAEAGLE CMS Cloud
The DATAEAGLE CMS Cloud is optimally suited for condition monitoring of e.g. engines and machines in industrial environments. The goal is to implement Remote Condition Monitoring in terms of Industry 4.0 simply and quickly. The data is therefore available in the Cloud for monitoring
DATAEAGLE CMS Cloud:
- 1 Multisensor for harsh industrial environments (CISS)
- IoT-Gateway (DATAEAGLE 2730) with integrated eSIM card for worldwide use
- Ready-to-use cloud dashboard (DATAEAGLE Portal) with API interface
DATAEAGLE CMS Fieldbus
The DATAEAGLE CMS Fieldbus is optimally suited for local condition monitoring of e.g. motors and machines in industrial environments. The aim is to implement condition monitoring in the sense of Industry 4.0 directly at the process via the controller. The data is therefore available for monitoring via a fieldbus interface
DATAEAGLE CMS Fieldbus:
- 1 Multisensor for harsh industrial environments (CISS)
- Industrial IoT Gateway (DATAEAGLE 2730) with fieldbus
- Pre-installed connection between BLE sensor and the gateway including integration project for the PLC
DATAEAGLE CMS Local Dashbaord
The DATAEAGLE CMS Local Dashboard is optimally suited for condition monitoring of e.g. engines and machines in industrial environments. The aim is to implement condition monitoring in the sense of Industry 4.0 simply, quickly and locally. For monitoring, the data is therefore available via Ethernet in a node-RED dashboard.
DATAEAGLE CMS Local Dashboard:
- 1 Multisensor for harsh industrial environments (CISS)
- Industrial IoT Gateway (DATAEAGLE 2730) with Ethernet
- Ready-to-use Node-RED dashboard with overview of all sensor values
- Sensor integrated to Grafana Dashboard & Data Analysis Interface
DATAEAGLE CMS PRTG Network Monitor
The DATAEAGLE CMS PRTG Network Monitor is ideally suited for condition monitoring of e.g. motors and machines in industrial environments and for retrofitting. The goal is to implement condition monitoring in the sense of Industry 4.0 simply, quickly and locally. For monitoring purposes, the data is therefore available via Ethernet in the PRTG Network Monitor.
DATAEAGLE CMS PRTG Network Monitor:
- 1 multisensor for harsh industrial environments (CISS).
- Industrial IoT gateway (DATAEAGLE 2730) with Modbus
- Ready-to-use dashboard with overview of all sensor values (PRTG license)
- Integration of OT and IT possible
Zubair Khan
Industrial Wireless Expert
If you have any questions about our products, please do not hesitate to contact me.
