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Prevent and Predict
Learn more about steps you can take to help reduce unplanned downtime, with this interactive guide.
Faulty relays or contactors
Contacts deteriorate over time, and coils can also fail. Consider replacing with high reliability solid state relays.
Electrical Preventive Measures
Cable flexing fatigue
For demanding applications consider very high performance, high flex cables.
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Will the back-up batteries work?
Back up batteries are a great safeguard against power outages, but only if they are in good working order.
Cable flexing fatigue
Protect cables subject to bending fatigue with cable chain.
Power supply voltage drops
Aging or poor condition PSUs can cause voltage drops, leading to equipment failure - replace the PSU with a high-reliability version.
Panel or terminal box moisture ingress can easily cause failures - upgrade to a higher IP enclosure.
Can be due to environment, or usage. Replace with higher IP versions, or ones capable of many more cycles.
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Take action to prevent the reoccurence of common electrical problems.
How accurate is the loop?
Degradation of components including sensors, valves, even PLC I/O cause the process to vary from its optimum parameters. Regularly monitor using process calibrators.
Take control. Monitor equipment performance and predict when you need to intervene.
Sensors degrading over time?
Upgrade to IO-Link sensors. They can provide information about their basic status, and report if maintenance is required.
Poor connections? Loading unbalance?
Sooner or later these and other electrical problems will cause breakdowns. Detect early using thermal imaging and intervene when convenient and necessary.
Could IIoT help me?
IIoT can offer convenient, mobile or remote access to devices or data, helping you to make decisions faster. Here we advise some key steps to take.
Electrical Predictive Activities
Mechanical Preventive Measures
Loose or poorly tensioned drive or timing belts can cause premature failures; check tension with a digital acoustic tension tester.
Prevent missed or under-lubrication occurring via the use of timed, controlled delivery auto-lubricators which can be mounted in place of a grease nipple.
Poorly aligned drive belts or pulleys can significantly contribute to noise, vibration and wear leading to premature bearing failure and costly machine downtime. Avoid this by using a laser guided belt alignment tool.
Which grease should I use?
Mixing greases can cause problems, with the different components reacting with each other; read our handy guide to ensure you use the right grease for your application.
Too much vibration
Vibration can accelerate wear and cause failures; fitting anti-vibration mounts can help dampen vibrations increasing uptime.
Prevent or reduce downtime resulting from mechanical wear or unexpected failures.
Machine Condition Monitoring
A simple and low cost way to add condition monitoring to existing pump, fan, gearbox or motor driven applications. The CMSS 200 tracks temperature and vibration levels, with threshold alarms to indicate significant variation.
Capture more data
Learn more about your processes, and how variables change over time using datalogging devices. Easy to configure and analyse results, they are available to cover a wide range of parameters.
Make repeatable, severity-scaled readings of overall vibration and bearing condition before a failure occurs with this portable vibration tester.
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Analyse your system to predict when failures could occur and take action before they do.
Mechanical Predictive Activities
Test for hot spots
Monitor areas you suspect of wearing to see how bad it is using thermal imaging; then you can intervene when it's necessary.
Leaks in air supplies
Air leaks in pneumatic systems can account for 20% of the systems energy cost and cause unforeseen breakdowns - check for air leaks regularly with leak detection spray and fix any you find.
Prevent and predict common problems with pneumatics and hydraulics systems.
Bring down the pressure
Reducing air pressure can save energy - and therefore cost - and extend component life. Fit additional pressure regulators to allow on-machine adjustment for optimum performance.
Pneumatic air quality
Poor quality, contaminated or under-lubricated air can drastically reduce the operational life of pneumatic actuators. Filter and lubricate air systems correctly to maximise component life.
Ultrasonic leak detection
Find air leaks using ultrasonics, which can also work on unpressurised or low pressure systems where the leak can be harder to find.