There are two approaches to IoT sensors, one side sees the value of wirelessly connecting sensors to remove the cost and difficulty in running cables. However this means relying on batteries, which may reduce the frequency of readings. The other approach is to wire each sensor for power and communication for reliability in the long term. We support both approaches and have components to meet the exact requirements of your application from temperature to accessibility.

Many systems today are designed around cloud based applications. This means that sensors communicate to a central hub which transmits the data to the cloud, where the information is converted into a dashboard. Users can log into the system to analyze trends and set up thresholds, so that alerts can be sent when the sensors detect issues. These cloud based systems have enhanced security programs to keep data safe and isolated from any machine control. However, some users prefer to use their own “on premises” software, which does not need to be broadcast from the facility. Sensors are wired directly to the system and dashboards are housed on the user’s IT network. This still allows for alerts and thresholds, but requires more internal capabilities from the user.

The sensors in an IoT condition monitoring system send data out, they are not designed to allow changes to the controls on a machine. The system provides alerts so that personnel at the facility can be notified of the issue, so that they can address it.

The exciting thing about emerging IoT technology is the ability to match the cost to the potential savings. For a complex and critical asset it might make sense to invest hundreds of thousands of dollars in precise measuring tools and robust monitoring systems. This investment will pay off by avoiding downtime, improving safety, and assuring production. However, the cost and complexity of less precise condition monitoring has been reduced to the point where it is possible to install condition monitoring on less critical systems for a fraction of the investment. By investing a few thousand dollars in tools and sensors a facility can realize the benefits of condition monitoring. The key is to match the level of monitoring to the costs of failure. The KIT team can help guide you to the system that makes the most sense for your facility.

The sensors in a condition monitoring system are recording a reading at regular intervals. These intervals are determined by the limitations of battery life and data storage. Some systems will constantly measure to identify intermittent spikes in the data, but only record measurements at a pre-determined interval. The key is that these sensors are not looking for the failure event, they are looking for the precursors to the failure event; the changes in vibration, temperature or other symptom of impending failure. The watchful eye on the monitoring dashboard is not a person at a screen, it is the thresholds that are set as triggers to alarms. These thresholds can be hard limits, such as a specific temperature, or they can be deviations from the norm that has been measured over time. Proper choices on how to set thresholds is a critical component of an effective condition monitoring system.