MonoDAQ Condition Based Monitoring (CBM) solution

MonoDAQ Condition Based
Monitoring (CBM) solution

MonoDAQ offers a revolutionary TOTAL solution (from hardware to software) for Permanent Condition Based Monitoring (CBM) applications. MonoDAQ E-CBM solution is designed with application critical requirements in mind while using the latest technologies available on the market. EtherCAT hardware architecture enables large distance distributed measurements (more than 50m node to node) with virtually limitless number of perfectly synchronized devices connected with a single network cable (delivering power and data). Fast and easy mounting of devices is facilitated by using RJ45 connectors. Single-channel solution is bringing the DAQ device very close to the sensor eliminating long analog cables and thus reducing noise pick-up and cost. Data Acquisition Software is used for data recording and analysis. Its main feature is to collect the data from all sensing points installed across the manufacturing facility and to deliver fully synchronized, trusted data for further cloud analysis and interpretation. 

MonoDAQ CBM solution enables its customers to detect:

  • Bearing faults
  • Overheating
  • Shaft un-balance
  • Detached mounting
  • Gear-tooth failure
  • Load misalignment
  • Stator excentricity

 

MonoDAQ CBM solution enables its customers to detect:

  • Bearing faults
  • Overheating
  • Shaft un-balance
  • Detached mounting
  • Gear-tooth failure
  • Load misalignment
  • Stator excentricity

 

MonoDAQ CBM Solution Core Features:

  • 0-10 kHz bandwidth, 50 g range, 25 μg√Hz noise density
  • EtherCAT bus, daisy-chaining with single cable up to 50 m device-device
  • Dewesoft X3 software support

Hardware:

  

MonoDAQ E-CBM Hardware is a vibration and temperature measurement device consisting of:

  • SNS-ACC-1-10k-F-2m: a 1-axis axis high bandwidth (10 kHz) and low noise vibration sensor probe which also includes temperature sensor and 3-axial low speed accelerometer for orientation identification
  • MonoDAQ-E-ASI-2-T: data acquisition device with 2 analog input chanels (with 40ks/S sampling speed per channel) for interfacing 2 MonoDAQ SNS-ACC-1-10k vibration probes and 1 digital input chanel for connecting an RPM sensor (tacho).

Hardware configuration is straightforward as presented in the sketch bellow. Powersupply and data signal are merged inside the MonoDAQ Power Injector (E-PWIN) module which connects the chain of devices to a Windows based PC running Dewesoft X3 Software.

Specifications of the sensor module:

  • 1-axis vibration accelerometer sensor specifications
  • temperature sensor specifications
  • 3-axis MEMS acceletometer specifications

Specifications of the data acquisition module:

Installation:

  

Data acquisition modules are daisy chained with a standard network cable. It is recommended that the cable is shielded (SFTP, CAT5e) and has a minimum 24 AWG wire thickness. The cable must have 4 wire pairs. The maximum distance node-to-node is 50 m. Power supply: Passive PoE power injector is necessary for merging the EtherCAT signal and power into a single cable.

The maximum number of Power Injector Modules per chain depends on the cable lenght between devices and power voltage.

PC software:

  

Dewesoft X3 software is very powerful but yet easy to use and plug&play. Each MonoDAQ CBM solution includes Dewesoft LT (Lite) license that offers hundreds of prepared calculation, display and analysis functions which help maintenance engineers find the machine problem and it's root cause.

In order to make maintenance engineer's life even easier, Dewesoft offers additional features and functionalities (on top of Dewesoft LT) in the Dewesoft PRO (Professional) license.

The most popular feature in the Dewesoft PRO license comparied to DEWESoft LT is the Envelope Detection:

- Envelope Detection (Demodulation): it is a procedure used for early detection of bearing component failures. The function also includes a large database of available bearings and their frequencies. BPFO, BPFO, Cage and Ball defect frequencies are automatically calculated by taking in consideration machine RPM and bearing model characteristics.

The most powerful Software package for CBM applications is Dewesoft Rotating Machinery Analyzer.

The most popular features in the Dewesoft Rotating Machinery Analyzer license compared to Dewesoft PRO are:

- Rotor Balancing module: Your rotor unbalance creates high noise and results in earlier machine defects. Detecting unbalance and performing balancing was never so intuitive and easy as with MonoDAQ Hardware and DEWESoft balancing module. Balancing module core features are:

  • Single or dual plane balancing on site
  • Simple step-by-step procedure
  • Rich visualization
  • Weight splitting
  • Storage of influence vectors

- Order Tracking module: It is a true ECG for machines. It is a perfect tool to determine the operating condition of the rotating machines (resonances, stable operation points, determiningn cause of vibrations). Order tracking enables you to analyze the performance of each part of the machine individually.

- Rotational and Torsional vibration: Torsional vibrations are quite often a source of issues and faults on the long shafts. Rotational and torsional vibration module is a tool to troubleshoot such issues in condition monitoring applications.

Rotational and Torsional vibration core features:

  • Easy sensor setup
  • Access to all data
  • Advanced math
  • Order tracking integration

- Octave Band Analysis: Due to its logarithmic frequency axis, octave analysis is an indispensable tool for sound measurement as well as predictive monitoring. Dewesoft octave analysis solution meets all of the IEC and ANSI Class I specifications for octave filters.

Octave Band Analysis core features:

  • True octave analysis
  • Synthesized analysis
  • Resolution up to 1/24 octave
  • Frequency sound weighting
  • Frequency averaging

Dewesoft software interface is translated into many languages.

Cloud software:

  

Cloud Software infrastructure is available for graphical representation of the machine state. It offers a visualization of long-term trends. On top of that thresholds and alarms are available to be used in combination with e-mail or SMS notifications. Final GUI (Graphical User Interface) can be easily customized according to customers requirements.

The computated data is streamed from Dewesoft software running on the local PC over OPC into a database. The database can run on a local server or in a cloud.

SCADA:

  

Data transfer from Dewesoft to SCADA is straightforward by using the Dewesoft OPC UA Server or Client extension modules. In this case Dewesoft SW acts as SCADA server or client, depending on the requirements set by the customer.

Industrial communication protocols:

  

OPC UA, Siemens S7, MODBUS, Serial communication and Ethernet communication protocols are supported within Dewesoft as optional upgrades.

Testimonials

Sandro Berchiolli, CEO, ISE Srl: 
MonoDAQ's solution modularity and flexibility have given us more opportunities and improved our CBM applications. Compact, easy to install and really powerful.

Sandro Berchiolli, CEO, ISE Srl: 
MonoDAQ's solution modularity and flexibility have given us more opportunities and improved our CBM applications. Compact, easy to install and really powerful.

Mauriccio Fachinetti (TOPFIBRA Managing Director):  
I was impressed by the professional approach of MonoDAQ personnel. After a thorough investigation they installed their permanent CBM solution that not only works but it saves a lot of money and time at my customers. On average they saved more than 40% on repair costs and increased the revenue by 15%. Amazing performance!

Mauriccio Fachinetti (TOPFIBRA Managing Director):  
I was impressed by the professional approach of MonoDAQ personnel. After a thorough investigation they installed their permanent CBM solution that not only works but it saves a lot of money and time at my customers. On average they saved more than 40% on repair costs and increased the revenue by 15%. Amazing performance!

Matej Kranjc (SCIMEAS Australia Managing Director):  
MonoDAQ is the only DAQ company that offers a single channel robust DAQ system accompanied with DAQ software with virtually limitless possibilities. After a thorough investigation the customer decided to equip all of its CNC machines with MonoDAQ CBM solution. After using the solution for one year the benefits of the MonoDAQ system are very clear. They reduced maintenance costs by 55% and increased profits by 3%! MonoDAQ, thank you for your support and wish you good luck!

Matej Kranjc (SCIMEAS Australia Managing Director):  
MonoDAQ is the only DAQ company that offers a single channel robust DAQ system accompanied with DAQ software with virtually limitless possibilities. After a thorough investigation the customer decided to equip all of its CNC machines with MonoDAQ CBM solution. After using the solution for one year the benefits of the MonoDAQ system are very clear. They reduced maintenance costs by 55% and increased profits by 3%! MonoDAQ, thank you for your support and wish you good luck!

Fadi Lama (YLE GmbH):  
MonoDAQ product line is a perfect fit for high fidelity, distributed CBM monitoring applications. What I really liked about MonoDAQ, on top of their product line, is their very professional and quick response support team.

Fadi Lama (YLE GmbH):  
MonoDAQ product line is a perfect fit for high fidelity, distributed CBM monitoring applications. What I really liked about MonoDAQ, on top of their product line, is their very professional and quick response support team.