SUCCESS STORY - Predictive Monitoring Deployment
Company Overview:
Founded in the early 1950’s, the company quickly became the world’s leading manufacturer of tubular heating elements and thermostats for water heaters.
In the following years, thanks to significant investments in R&D and production capacity, the company diversified by focusing on new business opportunities, becoming a leader also in the production of heating solutions for heat pups, household appliances, as well as professional and industrial applications.
Today, the company manufactures over 40 million pieces per year, serving more than 500 customers in 100 countries.
Predictive Maintenance Project
We recently successfully completed a predictive monitoring project at the customer’s industrial facility.
Project Objective
Installation of a wireless system for continuous monitoring of the operating conditions of critical machines, focusing on vibration and temperature, to prevent failures and optimize maintenance.
Project Background
We met the customer at their facility, visited the production area, and discussed both existing and potential issues (MTBF, MTTR of the machines). We focused in particular on the main problems caused by failures that had occurred on the presses, which are the most critical machines in the production lines.
Based on the information collected, we met the customer a second time and proposed the ERBESSD INSTRUMENTS solution because:
- It could ensure the detection of the operating status of critical components.
- It allowed for rapid installation.
- It provided simple local monitoring as well as the possibility of receiving remote support if needed.
During this second meeting, the customer approved and agreed with the proposal, deciding to start with an initial pilot installation.
In a single day, the sensors were installed on the machine, and both the Gateway and EI Analytic were configured. By the afternoon, the system was fully operational, and basic training was provided to the customer.
Technology Installed
EPH-V11E Sensors
The installed sensors are wireless triaxial devices for vibration and thermal monitoring. Key features:
- Measurement type: Acceleration, velocity, and displacement (3 axes), plus temperature
- Sampling frequency: Up to 25,600 Hz per axis, suitable for detailed FFT analysis
- Data transmission: Wireless
- Power supply: Long-life batter
- Protection rating: IP69–resistant to harsh industrial environments
- Mounting: Easy installation on machines, with simple battery replacement
These sensor enable early diagnosis of:
- Unbalance, misalignment, mechanical looseness
- Bearing defects, gearbox anomalies, resonance issues
- Abnormal thermal variations
Communication Gateway and Router
The system is completed by a Gateway that collects data and sends it to the analysis platform:
- Communication: Ethernet/Wi-Fi, supports MQTT and Modbus TCP protocols for integration
- Functions: Data collections, local buffering, cloud/software transmission
- Sensor management: Configuration, firmware updates, status monitoring (battery, signal, alarm activation)
- Router: Includes a router for remote data transmission via 4G
Activities Performed
- Physical installation of sensors on critical motors and gearboxes
- Full system configuration and communication testing
- Operational training for technical personnel on the diagnostic software
- Verification of correct data flow between devices and the supervisory system
Impact
The installed system enables proactive maintenance management, reducing unplanned downtime and improving he overall efficiency of production lines.
M.V. Industrial Group is a company that deals with supporting companies in the digitization processes by providing the most modern instruments and technological solutions to achieve the objectives that can guarantee their customers a rapid evolution.
ERBESSD INSTRUMENTS® is a leading manufacturer of Vibration Analysis Equipment, Dynamic Balancing Machines, and Condition Monitoring with facilities in Mexico, the USA, England, India, and Colombia.
Authored By: Nada Oxa, Sales & Marketing at M.V. Industrial Group