How To Avoid Mechanical Failure With IIoT

Mechanical failure is a constant source of frustration within manufacturing. It causes unplanned downtime, unexpected gaps in production, and lost revenue.
Traditional manufacturing processes view equipment performance from a control system perspective. But the  Industrial Internet of Things (IIoT) offers a new point of view. IIoT is a major technological advancement. It involves using connected devices, sensors, and software in industrial environments. These smart technologies can benefit industries like manufacturing, energy, transportation, and supply chain management.

Networked industrial equipment allows users to connect straight to mechanical assets. This gives a more comprehensive view of machinery. Not to mention a perspective that is more reliable, safe, precise and automated.

Equipment driven by a Programmable Logic Controller (or PLC) can talk in a data-specific language. Users have access algorithms that provide real-time performance analytics. These analytics deliver actionable alerts that:

• Define what is wrong with which piece of equipment,
• Explain what to do to resolve the issue,
• Provide a time frame within which the resolution needs to happen.

All with the intention of avoiding over maintaining and unplanned downtime.

Owning and operating an IIoT Smart Gear Drive will:

• Shorten the start-up/MTTR (mean time to repair),
• Increase up-time/MTBF (mean time between failure),
• Provide higher OEE (overall equipment effectiveness),
• Improve inventory management and maintenance costs, and
• Improve the accuracy of maintenance and replacement events for your operation.

Incorporating IIoT technology can make your life easier in three significant ways, through improving reliability and sustainability, promoting safety, and helping optimize your assets. 

Smart Devices Improve Reliability and Sustainability

Real-time data gives you a complete view of system health. For example, you can see if your oil is only 10 percent used or close to the end of its life. You can also track trends in temperature or vibration. On top of that, alerts can tell you what’s happening, where it’s happening, and what actions to take. All this can make a big difference in how you manage your assets. 

Digital Connectivity Puts Safety First

Digital connectivity lets users monitor equipment in real time. Monitoring can take place remotely. Users won't have to send technicians to inspect equipment in person. This is especially important when equipment is in remote, elevated, or hard-to-reach locations.

With IIoT technology, there's no longer a need to send someone out to check a gear unit, take an oil sample, or perform potentially unnecessary tasks. This improves safety and efficiency while reducing costs.

Remote Monitoring Can Help Optimize Your Assets

Understanding where your system is on its current life cycle—based on your plant, application, and environment—makes maintenance easier to plan and more timely. It also speeds up decisions around ordering spare parts before they’re urgently needed.

But can these advancements in IIoT technology truly deliver?

A recent mine installation showcased the power of IIoT technology. The system sent alerts about a specific coupling’s performance. The system detected an imbalance in the coupling and a hidden gear vibration. These user corrected these issues. The smart system solved a long-standing problem with the coupling. It also identified the gear vibration years before traditional inspections would have caught it.

The system also monitored the impact of blasting at the mine face. Due to high dust levels in the air, it flagged the need for gearbox maintenance. Email alerts were automatically sent to the maintenance team, allowing them to act quickly and effectively.

By helping maintain optimal running temperatures, the system extended lubricant life. This reduced the frequency of oil changes and eliminated unnecessary oil sampling. It also provided a clear percentage of oil life remaining. This gave the operator confidence that the lubricant was still performing as needed.

The Industrial Internet of Things and its ties to Industry 4.0 has proven to be an asset to the modern day factory. To learn more about IIoT, and the impact it could have on your operation, contact our experts.

For more information on Rexnord IIoT Solutions, visit Perceptiv.