Predictive maintenance helps predict potential equipment failure, allowing your operation to increase availability and avoid costly downtime. Predictive maintenance tools are a key component to successfully utilizing a predictive maintenance strategy.
In general, there are three types of predictive maintenance tools:
- Tools that sensor and generate data
- Tools that analyze and track
- Tools that schedule maintenance in the field
Sensors and Data Generating Tools
Sensors and data generating tools can alert about different machines without having to shut them down. They can detect differences in temperature, pressure, and operating efficiency, indicating the condition of your equipment.
These tools also collect data in real-time and share it in a centralized location. Finally, an algorithm analyzes this data and predicts when trends will need attention.
Analyzing and Monitoring Tools
Monitoring tools make changes and adjustments to machinery in real-time. Predictive analytics also improve other business-related processes like management, logistics, and procurement.
Maintenance Scheduling Tools
Maintenance scheduling solutions analyze many inputs including ongoing processes to optimize production and detect bottlenecks that may be affecting the process. They also assign resources based on the big picture.
The Best Predictive Maintenance Tools Available
Achieving operational excellence is a reachable goal with the best predictive maintenance tools. Here are a few:
- Vibration Analysis Sensors
- Motor Circuit Analyzers
- Infrared Analysis Sensors
- Laser-shaft Alignment Tools
- Ultrasonic Analysis Microphones
- Video Analysis Tools
Understanding how these tools work will help you run a best-in-class team.
Vibration Analysis Sensors
Vibration analysis sensors detect and analyze abnormal vibrations and patterns. Vibration on a machine is a common failure indicator.
Rotating machines are often subject to this kind of failure. Predictive analysis tools like vibration analysis sensors detect misalignment. They also detect
- Lack of lubrication
- Mechanical defects
A variety of assets can use vibration analysis sensors.
Motor Circuit Analyzers
The electrical health of your machinery is vital. Motor circuit analyzers give you a comprehensive view of a motor’s electrical efficiency. In addition, they use motors’ electrical components to track potential equipment failure.
They detect issues like
- Bearing abnormalities
- Stator winding
- Coupling issues
- Attached load issues
Infrared Analysis Sensors
Infrared analysis sensors can detect infrared radiation, indicating the temperature of an object, which the human eye cannot see.
These sensors compare the temperature differences of a piece of equipment’s components – if these differences are abnormal, the infrared analysis sensor will show a change. Infrared analysis sensors detect issues like
- Process temperatures
- Electrical components
- Insulation conditions
- Plumbing conditions
Laser-Shaft Alignment Tools
When equipment components are misaligned there is a risk of failure. Improper installation causes extreme pressure, and bearings especially suffer from misaligned shafts.
Laser-shaft alignment tools detect misalignment, helping to prevent failure, and aid in shaft alignment documentation. They also ensure proper shaft alignment verification and the reduction of mechanical failure.
Ultrasonic Analysis Microphones
Ultrasonic analysis tools prevent issues in machines by detecting high-frequency sounds. Then, they compare the sounds they detect with previous recordings and if there are abnormalities, they will show them.
Ultrasonic analysis microphones can detect issues like leaks and failed steam valves. They can also aid in lubrication processes, electrical inspection, and valve testing.
Oil Analysis Tools
The condition of a machine’s oil is important to its operational condition. Oil analysis tools test the oil’s water, viscosity, and other signs of wear.
These kinds of predictive tools are often used on critical or high-speed pieces of equipment. Oil analysis can detect the presence of metals indicating equipment wear.
Video Analysis Tools
Video analysis tools capture detailed vibrations of equipment and provide a realistic image of the equipment. These tools analyze the shapes of movement produced by the equipment as it works. This shape of movement is called Operating Deflection Shape, or ODS.
Why You Should Invest in Predictive Maintenance Tools
The main advantage of predictive maintenance is reduction in equipment failure. Predicting wear or failure before it happens helps you prevent total failure.
Another benefit of using predictive maintenance tools is increased asset life. Predictive maintenance tools detect minor issues that could lead to complete machine failure, prolonging the life of your equipment.
Finally, predictive maintenance tools show you how well the repairs on equipment work so that when damage occurs, you will know whether your repair team was successful.
Where to Find Predictive Maintenance Solutions
For more than 30 years and DINGO has provided predictive maintenance solutions to asset-intensive industries. We combine deep maintenance expertise with industry-leading technology in order to help mining companies implement solutions that continuously improve the health and performance of equipment. DINGO currently manages over $13 billion worth of heavy equipment, and our real-world solutions have generated over $750 million in cost savings.
Contact DINGO for a brief Asset Health Consultation or use our Savings Calculator to estimate the annual savings that your operation could achieve.