Asset and facility management technologies are increasingly sophisticated and effective. Machine health monitoring and control solutions that leverage built-in artificial intelligence (AI) and internet of things (IoT) sensors accelerate industrial revolutions and drive equipment reliability and performance to new heights.
Industry 4.0 and 5.0 enablers
The IO-Link communication standard facilitates Industry 4.0 by enabling the transfer of digital data directly from sensors on the factory floor. The 674A91 IO-Link Vibration Sensor from PCB Piezotronics provides a digital output of all the critical data parameters needed to monitor fault conditions such as imbalance, misalignment, bearing faults, and gear mesh failure, according to Matthew Negaard, manager of digital sensors at PCB Piezotronics.
“By combining our proven Piezoelectric sensor technology and an IO-Link digital interface, we lower the cost and effort of integrating the most comprehensive vibration monitoring to your factory operations,” observes Negaard. “The 674A91 allows you to skip traditional methods of converting analog signals in your factory and move right to two-way digital communication with an intelligent sensing device that is placed directly on your machine.”
Smart lighting sensors and associated Industry 4.0 technology enhance energy savings and code compliance. The line of IP66-rated Smart Fixture Mount Sensors (FMS) from Leviton combines occupancy sensing and 0-10V dimming control for warehouses, industrial locations, parking garages, parking lots, and building façade lighting.
Smart FMS sensors “use advanced digital PIR (passive infrared) technology to detect motion and can be mounted at any height from 8 feet to 40 feet,” says Reid Parks, product manager for controls at Leviton Manufacturing Co. For configuration, the Smart Sensor App is designed to be simple to use and walks the installer through all the important features and programming options, such as daylight harvesting and scheduling, he adds.
The new MiR1200 Pallet Jack from Mobile Industrial Robots (MiR) is an AI-powered autonomous mobile robot (AMR) that safely automates pallet transportation in industrial plant and warehouse environments. It promotes Industry 5.0 by helping to strengthen collaboration between humans and robots.
The MiR1200 Pallet Jack’s built-in AI perception system “enables unmatched picking accuracy with reduced pick-to-place cycle times,” says Mads Paulin, VP of R&D at MiR. “Combining AI and 3D lidar perception allows the pallet jack to detect when pallets might be placed in a slightly different location than originally expected or even damaged along the way. These are among the most challenging situations in autonomous material handling.”
Another Industry 5.0 enabler is smart conveyor belts that can assess their own health and wellness. The Connected Belt from Ammeraal Beltech (an AMMEGA brand) is designed to bring customers from reactive to predictive maintenance by delivering self-diagnostics and prognostics.
“The goal is to use smart technology to monitor the conveyor belt health, 24/7/365,” explains Bobby Bauman, director of product management at AMMEGA. “The AI-supported Ammeraal Beltech Connected Belt is an innovation in conveyor belting technology that transforms customer operations data into real-time actionable insights that support predictive and preventive maintenance scenarios and enrich Ammeraal Beltech data.”
Power distribution and grid optimization
Electrical safety and reliability advancements are always in focus. The EvoPacT ANSI from Schneider Electric is a Square D medium-voltage (MV) digital vacuum circuit breaker with embedded IoT sensors for proactive condition monitoring. The sensors generate alerts and recommend actions about components needing attention. Operators can remotely operate and control equipment from outside the arc flash zone, reducing safety risks.
“EvoPacT is the only MV breaker in the North American market available with physical sensors embedded inside the breaker to provide actual measurements of critical components, such as coils, motors, mechanisms, and vacuum interrupters (e-gap), putting focus on asset health and helping you switch to more proactive maintenance practice,” notes Tyler Morris, product owner at Schneider Electric.
The SICAM Enhanced Grid Sensor (EGS) from Siemens Smart Infrastructure is an all-in-one compact device that improves visibility and control for resilient and secure power grids. It combines versatile advanced measurement capabilities with a secure RTU gateway, increasing distribution network transparency and accelerating the energy transition.
The SICAM EGS “is ideal for electrical substations, low-voltage cabinets, and cable distribution cabinets and complies with the highest safety standards,” says Mikhail Rabinovich, automation, protection, and IoT product manager at Siemens. “It supports the integration of asset monitoring for transformers and switchgears, IoT gateway connectivity, and grid connection monitoring for distributed energy resources (DER) and electric vehicle (EV) charging stations.”
