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disynet GmbH
Breyeller Str. 2
41379 Brüggen (Germany)
Tel: +49 2157 8799-0
Fax: +49 2157 8799-22

disynet GmbH: the increasing importance of condition monitoring and predictive maintenance!

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To improve the lifespan of machines, the prevention of costly production losses and the optimization of overheads and maintenance costs, the application of sensors gains importance in predictive maintenance.

Predictive maintenance is more than mere condition monitoring; it not only describes the continuous monitoring of machines and manufacturing plants but also provides real-time analysis and algorithms to make predictions about the current maintenance condition.

The sensors give information about the physical parameters such as acceleration (e.g. engine vibration), force, pressure, oil condition (e.g. wear of gear), surface temperature etc. This information is analysed in real-time. The early diagnosis of problems and appropriate measures can increase the operational safety and the lifespan of machines significantly.
With condition monitoring plants are made fit for industry 4.0.

disynet GmbH provides a wide range of sensors for condition monitoring and, with suitable data acquisition, also for predictive maintenance.

There are many particle and wear-surveillance sensors on the market. Both, particle counters and wear monitor systems, provide a timely warning in case of foreign matter in lubrication systems. Metal particles in oil are always a sign of high wear in machines and the main reason for failure of such systems. Here disynet GmbH presents a multichannel debris-control System in two variants; one with an IP68-protected electronic module and one with an industrial display. Both can be used at 150°C in hot oils.

The "Oil Debris Sensor 4212" designed to detect metal wear and particles in oil, does not only continuously detect magnetic particles in hydraulic and lubricant oil systems, but also removes these using strong magnets. Furthermore it can distinguish the amount of contamination and size of the particles. With two output channels for fine particles (wear) and coarse particles (failure) it can continuously monitor the purity of the oil and also detect and notify deterioration of the quality of the oil in time. In addition to that it can also – depending on the requirement- either display water-in-oil contamination or the oil temperature.

Therefore, compared to vibration monitoring, this technology warns much earlier and enables the initiation of appropriate countermeasures more quickly.

The installation of the system is extremely simple and does not require any special training. The Oil debris sensor just has to replace the sump plug. If remote monitoring is needed, a mobile upload via GSM to a cloud-based server can be provided by a partner company.

Typical applications can be found in all gear-boxes, be it in motorsport, in agricultural or industrial plants, in wind-generators or in other heavy-duty branches.

disynet GmbH also provides sensors for other methods used in condition monitoring:

Vibration sensors are used to measure and record typical vibration and operating parameters. These recognise changes in vibration patterns, e.g. caused by wear in gear-oil. The ideal sensors for this purpose are industrial piezoelectric accelerometers which in addition should be robust and often also provide ATEX explosionproof. The 8711-, 8032 and the 8021 series are good examples for single axis sensors. If triax. sensors are required, the MTN/1330, a very robust sensors with IP66 watertight protection stainless steel housing is a good choice, covering a frequency response from 2 Hz to 9kHz.

A further method of condition monitoring is force-measurement of mounted mechanical parts. This can be done using the force-washer-sensors like the FMT, the XFL-225D or the 1210C series.

The scope of disynet GmbH is complemented by special Laser sensors for the quick and cost effective predictive maintenance. An example is for monitoring railway wheelsets. Other sensors for the railway sector disynet include the models IMR, IKP, IDK, which can continuously monitor the track wheels without much effort. The sensors are supplied with a software which also allows extremely simple analysis and recording of the data in a computer databank.

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