Industrial companies face an ever increasing pressure to reduce downtime and maintenance costs. Production delays and increased operating and maintenance costs are only some of the severe consequences that equipment failures can induce. Best-in-class manufacturing companies are already deploying predictive maintenance strategies to anticipate failures and optimize maintenance cycles. Those that have adopted such solutions have seen a reduction in unscheduled downtime of up to 45% and increase in production of 20% to 25%, based on a report published by the U.S. Department of Energy.
Another factor making existing condition-monitoring systems less feasible is the amount of resources required to collect, prepare and analyze the data. In the face of increasing skilled labor shortage, industrial companies just cannot afford to dedicate so much time and effort to go through the data and manually detect anomalies.
The importance of controlling maintenance costs is also evident if we look at the life cycle costs of pumps. In comparison to the initial investment, approx. 10% of the TCO, maintenance costs are rather high: 20% derive from maintenance and 10% from production downtime. If incipient failures could be identified in advance, maintenance managers could prevent components from being damaged and achieve significant cost reduction.
To help industrial clients respond to these challenges, KONUX offers an integrated vertical solution that makes predictive maintenance economical also for small- and medium-sized pump systems.
Our goal is to create a holistic MEMS-based retrofit sensor system combined with advanced analytics for affordable and user-friendly permanent online-monitoring. The compact retrofittable design of the sensing unit enables fast and easy mounting on pump housing in under 1 hour. Integrated in-sensor conditioning requires fewer data to be transferred, which drastically reduces power requirements and facilitates wireless communication. Wireless data transmission then eliminates expensive and time-consuming wiring and associated maintenance and offers greater flexibility. The KONUX retrofit sensor system for pump online-monitoring combines vibration and ultrasound measurements up to 10 kHz with the additional magnetic field, humidity and temperature measurements. It has an autonomous battery lifetime of one year, which can be extended by energy harvesting solutions.