DriveRadar® IoT Suite for industrial gear units
Condition monitoring and maintenance forecasting
Regardless of the industry in which you operate, unscheduled downtimes in production are the nightmare of every plant operator. Temporary production outages mean that costs soar instantly.
Think ahead and don’t let it get that far in the first place! DriveRadar® for industrial gear units is an ultra-modern condition monitoring system, which digitally records and automatically assesses gear unit data. The results of such analyses can be used to evaluate the current condition of gear units. Forecasts derived from this also allow you to predict future changes in condition. All the results and findings obtained serve as a basis for predictive maintenance.
An extensive package of sensors, with which your industrial gear unit is equipped, provides the database for this. These sensors capture all operationally relevant physical parameters: vibration behavior, oil level, oil temperature, ambient temperature and input speed.
Your benefits
Avoiding downtime
Reduced maintenance costs
Targeted
fault elimination
Transparency from any location
Resource
conservation
We’re here to help
Our experts know your industry and your requirements. Our global
network ensures we are close at hand wherever and whenever you need us.
A simple explanation of the operating principle
DriveRadar® for industrial gear units allows you to plan maintenance measures in advance – thereby avoiding unscheduled plant downtimes.
Sensors installed in the gear unit record physical parameters of the industrial gear unit that are of relevance to operation. The recorded data is then evaluated and interpreted on an automated basis. Continually monitoring the measured values ensures a transparent gear unit condition at all times.
The underlying analytical processes match irregularities directly to the affected components, reveal trends and make it possible to predict when critical conditions are likely to arise. Should a change in condition occur, the user is informed without delay. Options for eliminating the fault yourself as well as recommended services from SEW-EURODRIVE are both indicated.
1. Data acquisition
The sensors record the parameters of the industrial gear unit and forward these to the DriveRadar® EdgeProcessingUnit (EPU). The package of sensors comprises 2 × acceleration sensors, 1 × oil temperature sensor, 1 × ultrasound sensor, 1 × speed sensor and 1 × DriveRadar® EdgeProcessingUnit.
The sensors capture the following data:
- Operating hours
- Input speed and direction of rotation
- Vibration behavior of rolling bearings and gearing
- Oil level
- Oil temperature
- Oil viscosity
- Electronics temperature
- Ambient temperature
- Additional sensors can be connected
2. Data connection
The DriveRadar® EdgeProcessingUnit records all sensor data and transmits the collated measured values to the SEW-EURODRIVE data centers (certified in line with ISO/IEC 27001). The data is transmitted encrypted and at short intervals.
3. Data analysis
The raw data that has been collected is analyzed, interpreted and prepared in the SEW-EURODRIVE data centers:
- Vibration analysis at a constant and variable speed:
- Condition of individual bearings and their components (outer ring, inner ring, rolling elements)
- Condition of individual gearings (local gearing damage, circumferential gearing damage/wear)
- Forecast of remaining service life for rolling bearings and gearing:
Monitoring of statistical failure probability as a predictive addition to vibration analysis - Oil viscosity calculation
based on the oil temperature recorded and the oil grade used - Forecast for the next oil change:
Prediction of the next oil change due based on oil condition calculated according to use - Forecast of oil level:
Prediction of the time until a critical oil level is reached due to a decrease or increase in the fill level (due to e.g. oil loss, oil contamination) - Establishment of operating hours and idling times
4. Data visualization
The visualization in the DriveRadar® IoT Suite allows you to see the current condition of the gear unit and its components at a glance:
This provides your basis for intelligent predictive maintenance.
- Depending on the measured value, the limit values stored in the system are either taken from your specifications, adopted from the gear unit selection process or generated by the self-learning system itself within the first few months of operation.
- The system informs you when a limit value is exceeded and also provides direct recommended actions for solving your problem.
- You can request the appropriate services for your industrial gear units in the web application at any time or immediately after a system notification.
5. Data linking (OPC UA)
Using an OPC UA interface as standard also means measurement data and condition information can be incorporated directly into your customer system. If the traffic light displayed changes to amber or red ("Overall Health Status"), this tells you when you should take a look at your DriveRadar® IoT Suite.
The web application at a glance
All measured values are collated and visualized in the DriveRadar® IoT Suite.
Device list
The device list provides you with an overview of your industrial gear units. You can use filters and a grouping function to configure the view as you wish. A traffic light system simplifies continuous monitoring and ensures the user the transparency required in terms of gear unit condition, doing so in an intuitive way and at all times.
Overview of measured values and forecasts
Thanks to the visualization of condition and forecast values, you can see at a glance (everything is shown on one page) which measured values are OK or whether there are failures present.
- Compact overview of all relevant measured variables
- Vibration analysis and location of components
- Failure probability forecast for rolling bearings and gearing
- Oil level and oil change forecast
- Rapid access to contact and services
Detailed view and recommended actions
All historical data for a measured value is visualized in the detailed view. In the event of warnings and errors, you have the option of jumping straight to the time at which the incident was triggered.
- The recommended actions displayed help you rapidly eliminate the fault.
- If necessary, SEW-EURODRIVE can be easily contacted to request the appropriate services.
- An export function is provided for individual further processing of the displayed data.
What we offer
Alongside new gear units from the X..e series, DriveRadar® can also monitor gear units from SEW-EURODRIVE or other manufacturers that are already in use.
Hardware
Sensor package:
- 2 × acceleration sensors
- 1 × oil temperature sensor
- 1 × ultrasound sensor
- 1 × speed sensor
- 1 × DriveRadar® EdgeProcessingUnit
Access to the web application
Description:
- App for mobile devices included
- Data tariff for mobile service included
- Automatic notification of faults and warnings
Go to DriveRadar® IoT Suite web application
Downloads
All key aspects at a glance
We’re here to help
Our experts know your industry and your requirements. Our global
network ensures we are close at hand wherever and whenever you need us.
DriveRadar® IoT Suite for industrial gear units
Efficient maintenance thanks to automated condition monitoring by IoT (Internet of Things)
In the dynamic world of production, the standstill planner is a nightmare for system operators. Production downtimes immediately lead to rising costs. But there is one solution: Predictive action.
The digital recording and automatic evaluation of device data can be used to analyze and automatically predict system states. These forecasts make it possible to detect future changes in condition and thus plan preventive maintenance (predictive maintenance).
The basis for creating a sensor package for your industrial gear units. Sensors detect parameters relevant to operation such as vibrations, oil level, oil temperature, ambient temperature and input speed. Not only the industrial gear unit but also other components of the drive train can be monitored and analyzed.
Your benefits
Avoiding downtime
Maximizing service life
Efficient maintenance
Transparency from any location
Resource
conservation
A simple explanation of the operating principle
DriveRadar® for industrial gear units allows you to plan maintenance measures in advance – thereby avoiding unscheduled plant downtimes.
Sensors installed in the gear unit record physical parameters of the industrial gear unit that are of relevance to operation. The recorded data is then evaluated and interpreted on an automated basis. Continually monitoring the measured values ensures a transparent gear unit condition at all times.
The underlying analytical processes match irregularities directly to the affected components, reveal trends and make it possible to predict when critical conditions are likely to arise. Should a change in condition occur, the user is informed location-independent. Options for eliminating the fault yourself as well as recommended services from SEW-EURODRIVE are both indicated.
1. Data acquisition
Depending on the scope of the system, other components such as pedestal bearings or motors are monitored in addition to an industrial gear unit. For this purpose, the SmartSensor DriveRadar DUV40A is used, which can be used to extend the existing analysis functions to the other system components.
For industrial gear units, a comprehensive sensor package (consisting of 2 × acceleration sensors, 1 × oil temperature sensor, 1 × ultrasonic sensor, 1 × speed sensor and 1 × DriveRadar® EdgeProcessingUnit) records all the relevant data and forwards it to the EdgeProcessingUnit. The sensor data of the DUV40A is also collected and processed by the EdgeProcessingUnit.
The sensors capture the following data:
- Operating hours
- Input speed and direction of rotation
- Vibration behavior of rolling bearings and gearing
- Oil level
- Oil temperature
- Oil viscosity
- Electronics temperature
- Ambient temperature
- Additional sensors can be connected
2. Data connection
The DriveRadar® EdgeProcessingUnit records all sensor data of the industrial gear unit or the DUV40a connected via OPC UA and sends the measurement data encrypted via mobile radio to the SEW cloud, where it is processed and analyzed. The data plan is included.
3. Data analysis
The raw data that has been collected is analyzed, interpreted and prepared in the SEW-EURODRIVE data centers:
- Vibration analysis at a constant and variable speed:
- Condition of individual bearings and their components (outer ring, inner ring, rolling elements)
- Condition of individual gearings (local gearing damage, circumferential gearing damage/wear)
- Forecast of remaining service life for rolling bearings and gearing:
Prediction of residual component life as a predictive complement to vibration analysis
- Oil viscosity calculation
based on the oil temperature recorded and the oil grade used - Forecast for the next oil change: Prediction of the next oil change due based on oil condition calculated according to use
- Forecast of oil level:
Prediction of the time until a critical oil level is reached due to a decrease or increase in the fill level (due to e.g. oil loss, oil contamination) - Establishment of operating hours and idling times
4. Data visualization
With the visualization in the DriveRadar® IoT Suite, you can see at a glance the current status of the gear unit right through to the individual components:
Your basis for efficient maintenance.
- Depending on the measured value, the limit values stored in the system are either taken from your specifications, adopted from the gear unit selection process or generated by the self-learning system itself within the first few months of operation.
- The system informs you when a limit value is exceeded and also provides direct recommended actions for solving your problem.
- You can request the appropriate services for your industrial gear units in the web application at any time or immediately after a system notification.
5. Data linking (OPC UA)
By implementing an OPC UA interface as standard, measurement data and status information can also be integrated directly into your customer system. A higher-level overall health status as well as the raw data of the physical measured values are available.
The web application at a glance
All measured values are collated and visualized in the DriveRadar® IoT Suite.
Device list
The device list provides an overview of the monitored industrial gear units in your system. You can use filters and a grouping function to configure the view as you wish. A traffic light system simplifies continuous monitoring and ensures the user the transparency required in terms of gear unit condition, doing so in an intuitive way and at all times.
Overview of measured values and forecasts
Thanks to the visualization of condition and forecast values, you can see at a glance (everything is shown on one page) which measured values are OK or whether there are failures present.
- Compact overview of all relevant measured variables
- Vibration analysis and location of components
- Lifetime forecast for rolling bearings and gearing
- Oil level and oil change forecast
- Rapid access to contact and services
Detailed view and recommended actions
All historical data for a measured value is visualized in the detailed view. In the event of warnings and errors, you have the option of jumping straight to the time at which the incident was triggered.
- The recommended actions displayed help you rapidly eliminate the fault.
- If necessary, SEW-EURODRIVE can be easily contacted to request the appropriate services.
- An export function is provided for individual further processing of the displayed data.
DriveRadar® IoT Suite web application
- Login: DriveRadar® IoT Suite
- Get advice and receive 14 days of test access.
Write to us!
What we offer
Alongside new gear units from the X..e series, DriveRadar® can also monitor gear units from SEW-EURODRIVE or other manufacturers that are already in use.
Gear unit mointoring
Sensor package:
- 2 × acceleration sensors
- 1 × oil temperature sensor
- 1 × ultrasound sensor
- 1 × speed sensor
- 1 × DriveRadar® EdgeProcessingUnit
- optional: Integration of other measured variables
System monitoring
Your components
- DriveRadar® DUV40A
- Optional: Oil temperature measurement
Maintenance cockpit
Components
- Access to the DriveRadar® IoT Suite web application
- App for mobile devices included
- Automatic notification of errors and warnings
DriveRadar® IoT app – a mobile assistant
For all tasks throughout the entire product life cycle of one of our products
The app supports everything from installation and startup to maintenance and fault diagnostics. Technical data and documentation are provided in a product-specific manner and as step-by-step instructions.
All applications monitored with DriveRadar for industrial gear units are clearly displayed and all current measured values and associated limit values are displayed. In the event of status changes, the app immediately informs you with notification and initial recommendations for troubleshooting.
In summary:
- App for mobile devices included
- Automatic notification of errors and warnings
Our experts are there for you!
Try out our digital services free of charge for 14 days and get access to our internally monitored industrial gear units. Talk to us and discover how our solution optimizes your processes.
„+24“ extended warranty
for industrial gear units
Have you chosen our DriveRadar® IoT Suite monitoring system? Then order your X.e series industrial gear unit with factory oil filling and benefit from further advantages.
Your advantages with +24 smart:
- Additional 24-month warranty: Enjoy a free, extended warranty on your industrial gear unit.
- No first oil change: The first oil change after 500 operating hours is not required for gear units of the X.e. series
- Continuous monitoring: Benefit from continuous condition monitoring with the DriveRadar® IoT Suite.
Downloads
All key aspects at a glance
Go to download in Online Support:
Go to DriveRadar® IoT Suite web application
- Login: DriveRadar® IoT Suite
- Get advice and 14 days trial access.
Write to us!
We’re here to help
Our experts know your industry and your requirements. Our global
network ensures we are close at hand wherever and whenever you need us.