IIoT Wear Detection Sensor

MONITOR INDUSTRIAL ASSETS FOR WEAR & TEAR

PREDICT TIME TO FAILURE

Plan around to time-to-failure predictions. Receive warning about imminent asset failures.

MINIMIZE DOWNTIME

Control & optimize maintenance scheduling to minimize downtime & avoid unexpected shutdowns.

REDUCE LABOUR COSTS

Control & optimize maintenance scheduling to minimize downtime & avoid unexpected shutdowns.

REDUCE ENVIRONMENTAL RISK

Mitigate the risk of potential environmental breaches caused by asset failures.

The sensor

The Software

INSTALLATION

PDF MANUAL

AUTONOMOUS OPERATION

Wireless Data Retrieval

Real-Time Monitoring of Wear Rates

WIRELESS DATA RETRIEVAL

REAL-TIME MONITORING OF WEAR RATES

IIoT Sensor

An autonomous internal wear monitoring system measuring the internal abrasive wear in pipes, chutes, bins and wear plates and forecasting when maintenance is required.  Suitable for harsh environments, the sensor comprises of two parts:

1. the sacrificial probe

2. the transmitter

The sensor is installed in the field and is tasked with continuously measuring the wall thickness. of assets such as pipes, chutes, bins and wear plates that are exposed to abrasive production materials.

LEARN ABOUT THE PROBE

LEARN ABOUT THE TRANSMITTER

An innovative asset wear monitoring system that intelligently predicts and reports failures in:

PIPES  |  CHUTES  |  BINS  |  WEAR PLATES

…that are located in harsh environments and exposed to abrasive industrial slurries or other production materials.

Software Dashboard

Along with the wear-level status gauged by the sacrificial probe, the transmitter regularly reports its current battery-level back to the gateway (and, by extension, server) allowing the battery life to be monitored remotely.

If the batteries are running low, a notification can be sent automatically to technicians.  Temperature operating rated for -40 Degrees Celsius to +85 Degrees Celsius.

The sensor summary screen provides more detailed sensor information including battery level, signal strength, asset wear-level trends etc., allowing the health of each sensor to be maintained.

The system also generates reports which provide all the technical assets associated with a particular asset including:

  • access and installation requirements.
  • predicted date of failure
  • supporting technical documentation.

The Sacrificial Probe

$

Probe Installation on a Pipe Wall

 

The electronic circuit acts like a sequence of fuses. As the circuit wears down, electrical contacts progressively break. The number of breaks is constantly being interrogated by a microcontroller on the probe and reported back to the transmitter.

The probe circuit is available in any length to suit any asset!

The probe is an electronic circuit housed within a custom enclosure comprising similar properties to the asset wall being monitored. 

The probe is buried in the asset wall and is subjected to the same abrasive events, which results in the probe wearing at the same rate as the surrounding wall.

Different sizes, resolutions & enclosures can be provided on request.

The Transmitter

$

Exploded View of Transmitter & Probe

 

The transmitter runs on ultra-low power (typically under 5mW) and is capable of transmitting data over long distances (up to 8km).

This allows the device to run on a pair of standard, low-cost AA batteries for long periods without maintenance, thereby minimizing running costs. With default settings, the transmitter can operate for over a year without battery replacement – much longer than the life expectancy of most of the assets it will be monitoring.

 

Along with the wear-level from the Sacrificial Probe, the transmitter regularly reports its current battery-level back to the gateway (and, by extension, server) allowing the battery life to be monitored remotely. If the batteries are running low, a notification can be automatically sent to technicians.  Temperature operating rated for -40 Degrees Celsius to +85 Degrees Celsius.

Installation

1.

Following hazard identification and risk assessment, place thread tape on the male threaded end of the sacrificial probe enclosure. Screw the probe in a clockwise direction into the female thread on the pipe wear location. Screw in the probe until it has reached its destination. This will be calculated from the pipe specifications and take into consideration the thickness of the pipe and the probe length.

 

2.

Once the probe is in place use the locking nut to securely fix the probe into its final position.

 

 

3.

Connect the ribbon cable from the Transmitter to the socket on the Sacrificial Probe.

 

 

4.

Physically attach the Transmitter to the Sacrificial Probe by firmly screwing the locking ring on to the male thread on the probe enclosure (in clockwise rotation).

5.

Connect the ribbon cable from the Transmitter to the socket on the Sacrificial Probe.

 

 

Main Business Benefits

  • Reduce OPEX
  • Reduce risk of plant failures
  • Lengthen the life of assets
  • Increase plant uptime
  • Reduce risk of employee injuries
  • Improved operational efficiency
  • Reduce risk of environmental damage

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