Use cases

Continuous level measurement on tanks of a CIP system with moneo RTM and radar sensors

The non-contact level measurement principle with radar offers many advantages for monitoring a CIP system. Contact with media (acids, alkalis) and heating coils is avoided so that the measurement is independent of the temperature and density of the media. These advantages complete the quality assurance of the CIP cleaning process.

Pump monitoring in a CIP plant using the moneo SmartLimitWatcher

In this use case, a supply pump– one of the central elements of a CIP plant– is to be monitored in order to detect and signal any anomalies in time. The example illustrates the use of moneo|RTM for data recording and visualisation. Using the SmartLimitWatcher function of the DataScienceToolbox, a model is calculated that monitors the pump after a teach-in phase and reports any deviations.

Monitoring conductivity in a CIP plant

Ensuring process steps in process plant cleaning. Conductivity sensors are ideally suited for use in the food industry. They detect the conductivity and concentration of different media and can differentiate between e.g. cleaning agents, rinsing water, and the food product. This means that it is not only possible to constantly track the product but also to reduce the waste of product and rinsing water– all without making adjustments to the sensor. Precise, fast and reliable process measurements help to improve plant availability and optimise cleaning cycles.

Volumetric flow monitoring of a CIP plant using moneo RTM

Cleaning process control in the food and beverage industry When processing biological substances destined for consumption, such as milk, strict hygiene is vital. One of the decisive factors for a perfect cleaning result is the flow and thus the mechanical effect.

Temperature monitoring in a CIP plant

A CIP set is a process plant commonly found in the food and beverage industry, which undergoes cleaning in place (CIP). When processing biological substances destined for consumption, such as milk, strict hygiene is vital to prevent the introduction of harmful germs that could endanger the health of consumers.

Control cabinet monitoring protecting and monitoring components

Control cabinets are used as a space for mounting components to protect them against dirt, dust and moisture. They also provide heat dissipation, EMC shielding and contact protection. Monitoring of humidity, temperature, hotspots and the 24V supply with the aid of the ifm sensor system and moneo is available to ensure smooth functioning of a control cabinet. This makes it possible to draw conclusions about the operating status and prevent operational failures. How is this implemented? You can find out in our Use Case.

Monitoring the high-pressure oil filter by means of the differential pressure on a hydraulic test bench

Real time maintenance of an oil filter with moneo RTM. Filter monitoring plays an essential role in the smooth operation of production plants. In addition to air filters and water filters, condition monitoring of oil filters is of particular importance. Undetected soiling leads to consequential damage with possibly high follow-up costs. moneo RTM monitors the filters and is the basis for condition-based maintenance

Monitoring the water filters in cooling circuits with moneo RTM

Condition-based filter maintenance in systems with heat exchangers using moneo RTM Microfilters in ifm prover gmbh’s cooling circuits ensure that their systems with heat exchangers run smoothly. The filters protect the heat exchangers in the connected machines by removing impurities from the cooling water. This important filter element must be serviced and changed regularly. Permanent monitoring optimises this process and guarantees continuous operation of the systems.

Monitoring the air filters in production with moneo RTM

Visualisation and analysis of filter conditions. The central ventilation system at ifm prover gmbh is to be monitored. This includes the filters for the air supply and exhaust as well as the filters of the workstation exhaust system on the ground floor and the first floor. In principle, filters are, in simplified terms, a resistor in a system. Foreign particles that do not belong to the medium clog the open meshes or pores of the filter.

Keeping track of compressed air costs

The production processes of machine tools constantly require compressed air.

Compressed air production is one of the major cost factors in manufacturing. This is why energy efficiency measures have such a high potential.

Consumption metering via pulse outputs or an S0 interface using moneo RTM

With little effort and without interfering with existing systems, consumption data can be recorded and used to optimise energy consumption: On the one hand potential energy savings are shown, on the other hand it becomes evident where energy is wasted.

Consumption monitoring

Visualisation and analysis of the consumption of cooling circuits in production using moneo RTM

Level monitoring with replenishment control for a potting plant

With moneo RTM, the levels of casks filled with resin and hardener are monitored in a potting plant. When the levels reach a certain threshold, material replenishment is automatically ordered from the warehouse. By following this procedure, the quality of the manufactured products is upheld, while the risk of unplanned downtime is reduced.

Continuous level measurement on tanks of a CIP system with moneo RTM and radar sensors

The non-contact level measurement principle with radar offers many advantages for monitoring a CIP system. Contact with media (acids, alkalis) and heating coils is avoided so that the measurement is independent of the temperature and density of the media. These advantages complete the quality assurance of the CIP cleaning process.

Level monitoring in a calibration plant

Level monitoring on cold and hot water tanks. To ensure maximum measuring accuracy, both hot and cold water is sent through the sensors. The measured values are used for calibration.

Counting of workpiece carrier circulations using moneo RTM

Circulation counter in the plasma activation process of a production machine for electronic modules. The workpiece carriers in a production machine for electronic modules are subject to wear due to friction, impacts and plasma activation. To safeguard product quality, the workpiece carriers must be in faultless condition. Regular maintenance and replacement is thus necessary.

Quantity-based maintenance of wear parts using moneo RTM

Counting of embossing operations with a LOGO! mini controller. During the assembly of pressure sensors at a work station, parts for pressure sensors are embossed with an automatic embossing machine. The embossing stamp is particularly subject to wear. The level of wear primarily depends on the number of processed workpieces.

Optimised maintenance of wear parts at a final test station with moneo RTM

Change of maintenance strategy towards condition-based maintenance at ifm prover gmbh. Product quality is a significant success factor for ifm. For the purpose of quality control, a final inspection of pressure sensors is carried out at various workstations at ifm prover. Different types of production equipment are used. In some cases, electrical contact between the production equipment and the tested pressure sensors is established via an M12 connector. The constant friction caused by connecting the sensors results in wear of the socket on this connector. Consequently, the production equipment must be replaced regularly.

Counting of cycles on a knuckle-joint press

Quantity-based process monitoring for quality assurance

Piece counting of good/bad parts produced

At ifm prover, different components for pressure sensors are produced on an automated production plant. At the end of the production process, the good and bad parts are separated.

Continuous condition monitoring of fresh sludge and drainage pumps in the waste water industry

At the waste water treatment plant in Kressbronn, numerous pumps are monitored with the help of moneo. Vibration values and temperatures of these pumps are continuously recorded and possible cavitation is reported in good time. Implementing these measures effectively mitigates the risk of unplanned downtime for the waste water treatment plant, ensuring overall stability and reliability of the entire municipal waste water disposal system.

IO-Link vibration monitoring of fans in a central extraction system

The fans of an extraction system in the production hall are of crucial importance. Soldering vapours and fine dusts resulting from laser marking must be properly extracted. Otherwise, quality losses, health risks due to soldering vapours and a complete production standstill can be the result. Without monitoring of the fans, no preventive measures can be taken.

Wire feed motor current monitoring system improves robotic welding performance

ifm’s moneo Real-Time Monitoring System improves robot welding performance by monitoring the current of weld feed speed to the welding gun. Overload and underload spikes are identified and allows the operator the opportunity to correct the wire feed for uninterrupted production.

Detecting the operating status of a compressor based on the current consumption

Detecting the operating hours of a compressor based on the operating status. The correct functioning of a compressor is essential for the production processes. The availability of a compressor has an enormous impact on many production-relevant systems and processes.

Condition monitoring of a fan based on the current consumption

Detecting the quality of the phase currents on a fan of an exhaust system for the needs-based organisation of maintenance units.

Continuous condition monitoring of a decanter in the wastewater industry

A decanter will be monitored in the wastewater treatment plant in Kressbronn by integrating moneo. This will prevent unplanned downtime and ensure the entire municipal wastewater disposal system. An overview of the data for the newly installed vibration and temperature sensors on the motors, bearing and centrifuge will be provided by moneo.

Condition monitoring of a decanter for the recovery of clean water with moneo RTM.

Water treatment takes place mainly in the decanter. Monitoring is therefore necessary to ensure that chemicals are disposed of in accordance with wastewater regulations during the ongoing manufacturing process of flexible printed circuits. If there is a defect in the decanter, the entire production of flexible printed circuits must be stopped as the chemical disposal downstream of the manufacturing process by means of the decanter is equally decisive for the overall process.

Monitoring the bladder accumulator of a hydraulic system with moneo RTM

Bladder accumulators - like diaphragm, piston or spring accumulators- are hydraulic accumulators. In a hydraulic system, the bladder accumulator ensures volume compensation, energy storage, and dampens pulsations.

Monitoring the hydraulic power unit of a hydraulic test bench

The hydraulic power unit is the central component of a hydraulic test bench, which is used to test and qualify pressure sensors. Using comprehensive condition monitoring, wear and faults can be detected early, running times can be calculated and unplanned downtime can be prevented.

Machine tool: Energy meter with Modbus TCP interface

Energy consumption is an ever greater consideration for a machine tool. When there are numerous internal consumers, energy consumption should be monitored in regards to reactive power to reduce energy costs.

Keeping track of compressed air costs

The production processes of machine tools constantly require compressed air.

Compressed air production is one of the major cost factors in manufacturing. This is why energy efficiency measures have such a high potential.

Metering, visualisation and analysis of electrical energy using energy meters with Modbus TCP interface and moneo RTM

Companies are increasingly focusing on production-level energy monitoring to allow for more efficient, sustainable and forward-looking planning. Information about possible reactive currents can be used to implement suitable solutions for reactive power compensation and thus avoid unnecessary costs. For this purpose, energy meters are used.

Monitoring of the cooling circuit for the fermentation tanks at the Steinhauser distillery

In the production process of wines and spirits, the fermentation process is essential. During this process, the temperature must be monitored at all times to ensure optimum taste and quality of the products. If the fermentation process is to be slowed down or stopped, for example, the product is cooled down in the tank. Even a small deviation in the fermentation time can result in a considerable loss of flavour.

Roller chain monitoring at a demo setup

At present, ifm does not have an appropriate application that necessitates the use of a chain sensor. To show the full functional capabilities of the chain sensor in interaction with moneo RTM, an appropriate demo setup featuring a chain drive was installed and connected to the live moneo system.

Continuous condition monitoring of a decanter in the wastewater industry

A decanter will be monitored in the wastewater treatment plant in Kressbronn by integrating moneo. This will prevent unplanned downtime and ensure the entire municipal wastewater disposal system. An overview of the data for the newly installed vibration and temperature sensors on the motors, bearing and centrifuge will be provided by moneo.

Continuous condition monitoring of fresh sludge and drainage pumps in the waste water industry

At the waste water treatment plant in Kressbronn, numerous pumps are monitored with the help of moneo. Vibration values and temperatures of these pumps are continuously recorded and possible cavitation is reported in good time. Implementing these measures effectively mitigates the risk of unplanned downtime for the waste water treatment plant, ensuring overall stability and reliability of the entire municipal waste water disposal system.

Machine tool: Energy meter with Modbus TCP interface

Energy consumption is an ever greater consideration for a machine tool. When there are numerous internal consumers, energy consumption should be monitored in regards to reactive power to reduce energy costs.