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DriveRadar® IoT Suite for industrial gear units


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DriveRadar® IoT Suite for industrial gear units

Efficient maintenance thanks to automated condition monitoring by IoT (Internet of Things)


In the dynamic world of production, the standstill planner is a nightmare for system operators. Production downtimes immediately lead to rising costs. But there is one solution: Predictive action.

The digital recording and automatic evaluation of device data can be used to analyse and automatically predict system states. These forecasts make it possible to detect future changes in condition and thus plan preventive maintenance (predictive maintenance).

The basis for creating a sensor package for your industrial gear units. Sensors detect parameters relevant to operation such as vibrations, oil level, oil temperature, ambient temperature and input speed. Not only the industrial gear unit but also other components of the drive train can be monitored and analysed.

Your benefits

Avoiding downtime


Transparency about the condition of gear units and forecasts for critical changes in condition make predictive and needs-based maintenance possible.

Maximising service life


The condition-based planning of service and maintenance measures greatly extends your maintenance intervals.

Efficient maintenance


Automated localisation of causes and appropriate recommendations for action make it possible to implement maintenance measures in a targeted manner.

Transparency from any location


The easy-to-use web application creates a rapid overview of the condition of gear units and components online and issues email or app-based notifications.

Resource
conservation


Maximising the oil service life by determining the usage-dependent oil condition and the targeted replacement of rolling bearings, for example, make optimum use of parts possible.

A simple explanation of the operating principle

DriveRadar® for industrial gear units allows you to plan maintenance measures in advance – thereby avoiding unscheduled plant downtimes.


Sensors installed in the gear unit record physical parameters of the industrial gear unit that are of relevance to operation. The recorded data is then evaluated and interpreted on an automated basis. Continually monitoring the measured values ensures a transparent gear unit condition at all times.

The underlying analytical processes match irregularities directly to the affected components, reveal trends and make it possible to predict when critical conditions are likely to arise. Should a change in condition occur, the user is informed location-independent. Options for eliminating the fault yourself as well as recommended services from SEW-EURODRIVE are both indicated.

DriveRadar® operating principle

1. Data acquisition

Depending on the scope of the system, other components such as pedestal bearings or motors are monitored in addition to an industrial gear unit. For this purpose, the SmartSensor DriveRadar DUV40A is used, which can be used to extend the existing analysis functions to the other system components.

For industrial gear units, a comprehensive sensor package (consisting of 2 × acceleration sensors, 1 × oil temperature sensor, 1 × ultrasonic sensor, 1 × speed sensor and 1 × DriveRadar® EdgeProcessingUnit) records all the relevant data and forwards it to the EdgeProcessingUnit. The sensor data of the DUV40A is also collected and processed by the EdgeProcessingUnit.



The sensors capture the following data:

  • Operating hours
  • Input speed and direction of rotation
  • Vibration behavior of rolling bearings and gearing
  • Oil level
  • Oil temperature
  • Oil viscosity
  • Electronics temperature
  • Ambient temperature
  • Additional sensors can be connected

2. Data connection

The DriveRadar® EdgeProcessingUnit records all sensor data of the industrial gear unit or the DUV40a connected via OPC UA and sends the measurement data encrypted via mobile radio to the SEW cloud, where it is processed and analysed. The data plan is included.

3. Data analysis

The raw data that has been collected is analysed, interpreted and prepared in the SEW-EURODRIVE data centers:

  • Vibration analysis at a constant and variable speed:
    • Condition of individual bearings and their components (outer ring, inner ring, rolling elements)
    • Condition of individual gearings (local gearing damage, circumferential gearing damage/wear)
  • Forecast of remaining service life for rolling bearings and gearing:
    Prediction of residual component life as a predictive complement to vibration analysis




  • Oil viscosity calculation
    based on the oil temperature recorded and the oil grade used
  • Forecast for the next oil change: Prediction of the next oil change due based on oil condition calculated according to use
  • Forecast of oil level:
    Prediction of the time until a critical oil level is reached due to a decrease or increase in the fill level (due to e.g. oil loss, oil contamination)
  • Establishment of operating hours and idling times

4. Data visualisation

With the visualisation in the DriveRadar® IoT Suite, you can see at a glance the current status of the gear unit right through to the individual components:
Your basis for efficient maintenance.

  • Depending on the measured value, the limit values stored in the system are either taken from your specifications, adopted from the gear unit selection process or generated by the self-learning system itself within the first few months of operation.
  • The system informs you when a limit value is exceeded and also provides direct recommended actions for solving your problem.
  • You can request the appropriate services for your industrial gear units in the web application at any time or immediately after a system notification.

5. Data linking (OPC UA)

By implementing an OPC UA interface as standard, measurement data and status information can also be integrated directly into your customer system. A higher-level overall health status as well as the raw data of the physical measured values are available.

The web application at a glance

All measured values are collated and visualized in the DriveRadar® IoT Suite.


Device list


The device list provides an overview of the monitored industrial gear units in your system. You can use filters and a grouping function to configure the view as you wish. A traffic light system simplifies continuous monitoring and ensures the user the transparency required in terms of gear unit condition, doing so in an intuitive way and at all times.

DriveRadar® IoT Suite / Device list view

Overview of measured values and forecasts


Thanks to the visualisation of condition and forecast values, you can see at a glance (everything is shown on one page) which measured values are OK or whether there are failures present.

  • Compact overview of all relevant measured variables
  • Vibration analysis and location of components
  • Lifetime forecast for rolling bearings and gearing
  • Oil level and oil change forecast
  • Rapid access to contact and services
DriveRadar® IoT Suite / Overview of measured values and forecast

Detailed view and recommended actions


All historical data for a measured value is visualized in the detailed view. In the event of warnings and errors, you have the option of jumping straight to the time at which the incident was triggered.

  • The recommended actions displayed help you rapidly eliminate the fault.
  • If necessary, SEW-EURODRIVE can be easily contacted to request the appropriate services.
  • An export function is provided for individual further processing of the displayed data.
DriveRadar® IoT Suite / Recommended actions view

DriveRadar® IoT Suite web application


DriveRadar® IoT Suite / Recommended actions view

What we offer

Alongside new gear units from the X..e series, DriveRadar® can also monitor gear units from SEW-EURODRIVE or other manufacturers that are already in use.

Gear unit mointoring

Cross section of industrial gear units

Sensor package:

  • 2 × acceleration sensors
  • 1 × oil temperature sensor
  • 1 × ultrasound sensor
  • 1 × speed sensor
  • 1 × DriveRadar® EdgeProcessingUnit
  • optional: Integration of other measured variables

System monitoring

Industrial gear unit with motor with stylized insight into the motor and graphic line elements

Your components

  • DriveRadar® DUV40A
  • Optional: Oil temperature measurement

Maintenance cockpit

DriveRadar® IoT Suite desktop view

Components

  • Access to the DriveRadar® IoT Suite web application
  • App for mobile devices included
  • Automatic notification of errors and warnings

DriveRadar® IoT app – a mobile assistant

For all tasks throughout the entire product life cycle of one of our products

The app supports everything from installation and startup to maintenance and fault diagnostics. Technical data and documentation are provided in a product-specific manner and as step-by-step instructions.

All applications monitored with DriveRadar for industrial gear units are clearly displayed and all current measured values and associated limit values are displayed. In the event of status changes, the app immediately informs you with notification and initial recommendations for troubleshooting.

In summary:

- App for mobile devices included

- Automatic notification of errors and warnings


The app is available for download! The app is available for download!

Our experts are there for you!

Try out our digital services free of charge for 14 days and get access to our internally monitored industrial gear units. Talk to us and discover how our solution optimises your processes.

Request now

„+24“ extended warranty
for industrial gear units

Have you chosen our DriveRadar® IoT Suite monitoring system? Then order your X.e series industrial gear unit with factory oil filling and benefit from further advantages.


Your advantages with +24 smart:

  • Additional 24-month warranty: Enjoy a free, extended warranty on your industrial gear unit.
  • No first oil change: The first oil change after 500 operating hours is not required for gear units of the X.e. series
  • Continuous monitoring: Benefit from continuous condition monitoring with the DriveRadar® IoT Suite.


Downloads

All key aspects at a glance

Go to download in Online Support:

Go to DriveRadar® IoT Suite web application

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network ensures we are close at hand wherever and whenever you need us.

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