Mitsubishi Electric’s Smart Condition Monitoring (SCM) solutions use an intelligent sensor controller to provide an overview of plant operations using traffic-light style alerts. Integrated within this as detailed diagnostics, in-depth analysis and recommended actions to minimise unscheduled downtime and maximise asset availability.

Replaces vibration analysis

For example, in rotating machines, increases in operating temperature, excessive current draw, changes in vibration characteristics and significant shifts in other operating parameters can all be indicative of impending problems. By replacing vibration analysis and associated software with smart sensors has revolutionised condition monitoring.

The approach offers a basic indication of a machine’s operating condition using a traffic light system of red, amber and green lights provided ‘at-a-glance’ monitoring. However, behind this the technology has now been developed to allow the sensors to monitor the full range of parameters, allowing this information to be interpreted to give an overview on the asset health of the plant.  Unplanned downtime is reduced, and schedule maintenance for key assets more effectively managed.

Network enabled

Mitsubishi Electric’s SCM Kit solution that uses the latest advanced FAG SmartCheck sensors for monitoring and feedback. The Kit provides an integrated approach to monitoring the condition of individual assets, and enables a holistic approach to be taken to monitoring the asset health of the whole plant. Individual sensors retain the traffic light system for local warning indication at the machine, but simultaneously transfer information by Ethernet from multiple devices to the intelligent sensor controller or Mitsubishi Electric PLC) for in-depth monitoring and more detailed analysis.

The SCM Kit provides a plug-and-play solution for machine condition monitoring. SmartCheck sensors can be added to machines as and where required, with a simple teach function allowing the sensor and controller to learn the normal operating state of the machine, generating a memory map of key parameters. Once set up, the SCM provides 24/7 monitoring of each asset, with functions including bearing defect detection, imbalance detection, misalignment detection, lack of lubricant, temperature measurement, cavitation detection, phase failure recognition and resonance frequency detection.

Pattern analysis

Linking multiple sensors into the control system enables the controller to analyse patterns of operation that are outside the norm, with a series of alarm conditions that can provide alerts that attention is needed. The SCM analysis provides detailed diagnostics, offers suggestions for where additional measurements should be taken, and provides maintenance staff with more precise error identification. It even provides recommendations as to what rectification actions should be taken, with clear text messages presented to personnel, or networked to higher-level systems for ongoing trend analysis.