Industrial Wireless Automation: Advanced Condition Monitoring

The manufacturing sector increasingly leveraging advanced technologies to streamline operations and enhance efficiency. 

The adoption of industrial wireless automation, in the form of IO-Link Wireless, has proven impressively efficient, especially for advanced condition monitoring. Understanding how condition monitoring has changed with the appearance of wireless connectivity can help make educated decisions about manufacturing processes. 

What is Advanced Condition Monitoring?

Advanced condition monitoring is an integral part of predictive maintenance strategies. It highlights a shift from traditional reactive maintenance models to a more data-driven approach.

The process involves continuous monitoring of equipment conditions, using various parameters such as vibration, temperature, and humidity. These help predict potential failures before they occur. 

This methodology not only prevents downtime but also extends the lifespan of machinery and enhances factory operations. 

How Industrial Wireless Automation Enables Advanced Condition Monitoring

Industrial wireless automation transformed the landscape of advanced condition monitoring. For some manufacturing processes, it fundamentally altered the approach to predictive equipment maintenance.

• Elimination of Physical Constraints
  Traditionally, the reliance on cabling to connect sensors and devices for condition monitoring presented several challenges. They included installation complexity, high costs, and inflexibility to changes in the manufacturing layout. Harnessing the capabilities of IO-Link Wireless for industrial wireless automation removed these barriers by leveraging wireless communication capabilities. This evolution doesn’t just simplify the installation process but also reduces the time and expense involved in handling monitoring systems. The absence of physical wiring means that sensors can be placed in optimal locations for data collection, regardless of environmental obstacles.
• Enhanced Flexibility and Scalability
  One of the most significant advantages of industrial wireless automation is its flexibility. Manufacturers can easily add, remove, or relocate sensors without worrying about the constraints of wired infrastructure. This capability is particularly beneficial in dynamic manufacturing environments where changes to the production line are frequent. Wireless systems can adapt to new configurations with minimal disruption. They make sure that condition monitoring remains consistent and comprehensive across all operational adjustments.
• Access to Previously Inaccessible Data
  The ability to deploy sensors in previously hard-to-reach or hazardous areas opens up new possibilities for condition monitoring. For example, sensors can now be placed in high-temperature zones, within moving machinery, or in tightly confined spaces, previously inaccessible due to cabling, all thanks to the capabilities of IO-Link Wireless devices. This comprehensive coverage gives manufacturers a holistic view of their operations, capturing previously unattainable data points. By gaining insights into every aspect of machine health and performance, factories can identify subtle signs of wear and inefficiency.
• Real-time Data for Proactive Decision Making
  Industrial wireless automation facilitates the real-time collection and transmission of data from sensors to monitoring systems and decision-makers. This immediacy ensures that any anomalies, deviations from normal operating conditions, or signs of deterioration are detected timely. Real-time data analytics enable predictive maintenance strategies. This proactive approach minimizes interruptions to production, optimizes maintenance schedules, and extends the lifespan of equipment, by attending to malfunctioned parts, before significant harm is done.
• Integration with Advanced Analytics and AI
  The rich data streams generated by IO-Link Wireless sensors can be integrated with advanced analytics platforms and AI algorithms. These technologies can analyze trends, predict future performance, and recommend actions to prevent failures.

The Role of Industrial Wireless Solutions in Advanced Condition Monitoring

Designed to overcome the constraints of wired connections and traditional wireless protocols, IO-Link Wireless offers a robust means of wireless communications. Its benefits include:

• High Reliability: With a Packet Error Rate (PER) of 1e-9, IO-Link Wireless ensures reliable data transmission, critical for real-time monitoring.
• Low Latency: The deterministic nature of IO-Link Wireless guarantees data packets are delivered within a bound delay.

• Adaptivity: IO-Link Wireless supports a vast array of applications, from machine components that rotate rapidly to mobile systems, expanding the possibilities of condition monitoring.

• Seamless Integration: Offering easy connectivity to the cloud and compatibility with existing IO-Link infrastructure, it simplifies integration into current factory setups.

By implementing IO-Link Wireless, factories are reinventing the condition monitoring process and reaping the related benefits. 

Benefits of Advanced Condition Monitoring

The adoption of advanced condition monitoring powered by industrial wireless automation and IO-Link Wireless solutions brings many benefits to the manufacturing sector. These include:

• Reduced Downtime
  Advanced condition monitoring systems utilize predictive analytics to identify equipment anomalies and potential failures before they escalate. This foresight allows manufacturers to schedule preventive maintenance during non-peak hours. The ability to anticipate and mitigate issues before they lead to shutdowns is crucial for maintaining continuous operational flow.
• Cost Savings
  The shift from reactive to proactive maintenance strategies directly translates to cost savings. By avoiding emergency repairs, which often incur higher labor and part costs, manufacturers can significantly reduce their maintenance expenditure. Furthermore, extending the lifespan of machinery through regular upkeep decreases the long-term capital costs associated with equipment replacement.
• Increased Efficiency
  With access to real-time data analytics, manufacturers are empowered to make informed decisions that streamline operations. Advanced condition monitoring allows them to analyze data from various sensors to provide insights into machine performance and operational bottlenecks.
• Enhanced Safety
  Early detection of equipment malfunctions and failure risks can prevent accidents and injuries. This creates a safer environment for personnel. For instance, monitoring for overheating in machinery can help avoid fire hazards, while detecting mechanical wear can prevent catastrophic equipment failures.

Choosing the Right Industrial Wireless Technology for Condition Monitoring

Selecting the ideal wireless technology for condition monitoring involves considering several factors, such as the environment’s harshness, the required data rate, and the scale of the deployment. 

IO-Link Wireless, with its high reliability, low latency, and deterministic data delivery, presents a compelling option for manufacturers.

Making the Most Out of the Latest Monitoring Technologies

As the manufacturing industry progresses towards Industry 4.0, the role of industrial wireless automation in enabling advanced condition monitoring can’t be overstated. IO-Link Wireless, in particular, represents a significant advancement, offering a flexible solution for capturing critical data and analytics. 

By adopting these technologies, manufacturers can anticipate equipment failures, optimize maintenance schedules, and significantly reduce operational costs. 

Reid is an experienced executive with 35+ years of global OEM and enterprise account sales, business unit, and business strategy leadership experience at Rockwell Automation, prior to joining CoreTigo. Reid has diverse industry experience in meeting customer’s needs in auto, tire, food, beverage, consumer goods, and heavy industries. His role as Global OEM Business Director, where he led strategy development and sales execution for the $600M manufacturing & assembly OEM segment, prepared him to lead CoreTigo’s efforts to help North America machine builders differentiate their offerings. In his last role at Rockwell Automation, Reid was Director of Connected Enterprise Consulting Partnerships and was focused on client needs to leverage IIoT to drive value within their operations.
Reid holds a Bachelor’s Degree (B.Sc) in Electrical Engineering and a Master’s Degree of Business Administration (MBA) from the University of Michigan.