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DriveRadar® IoT Suite for industrial gearboxes


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DriveRadar® IoT Suite for industrial gearboxes

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


In the dynamic world of production, unplanned idle states are a nightmare for plant operators. Production downtime immediately leads to rising costs. But there is a solution: proactive action.

By digitally recording and automatically evaluating device data, plant conditions can be analysed and automatically predicted. These forecasts make it possible to recognise future changes in condition and thus plan preventive maintenance work (predictive maintenance).

The basis for this is a customised sensor package on your industrial gearbox. Sensors record operationally relevant variables such as oscillation, oil level, oil temperature, ambient temperature and input speed. Not only the industrial gearbox, but also other components of the drive train can be monitored and analysed.

Your added value

Avoidance of idle states

Maximisation of service life

Efficient maintenance

Location-independent transparency

Conservation of
resources

Operating principle simply explained

DriveRadar®® for industrial gearboxes makes it possible to plan maintenance measures in advance - thus avoiding unplanned plant downtimes.

Sensor technology installed in the drive solution records physical parameters relevant to operation, which are then automatically analysed and interpreted. Continuous monitoring of the measured values ensures the transparent status of the monitored devices at all times.

The underlying analysis methods assign anomalies directly to the affected components, display the trend and enable critical conditions to be predicted. If a change in the status of your drive technology occurs, the user is informed of this regardless of location. Both options for independent fault elimination and recommended services from SEW-EURODRIVE are displayed.

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 gearbox. The SmartSensor DriveRadar® DUV40A is used for this purpose, with which the existing analysis functions can also be extended to the other system components.

For industrial gearboxes, 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 operation-relevant data and forwards it to the EdgeProcessingUnit. The sensor data from the DUV40A is also collected by the EdgeProcessingUnit and processed further.


The following data is recorded by the sensors:

  • Operating hours
  • Input speed and direction of rotation
  • Vibration behaviour of rolling bearings and gearing
  • Oil fill level
  • Oil temperature
  • Oil viscosity
  • Electronics temperature
  • Ambient temperature
  • Further sensor technology can be connected

2nd data connection

The DriveRadar® EdgeProcessingUnit records all sensor data from 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 further processed and analysed. The data tariff is included.

3. data analysis

The collected raw data is analysed, interpreted and processed in the SEW-EURODRIVE data centres:

  • Vibration analysis at constant and variable rotational speed:
    • Condition of the individual storages and their components
    • Condition of the individual gearing
  • Forecast of the service life of rolling bearings and gearing:
    Prediction of component residual life as a predictive supplement to vibration analysis




  • Calculation of oil viscosity
    based on the recorded oil temperature and the type of oil used
  • Forecast of the next oil change:
    Prediction of the next oil change due based on the usage-dependent calculated oil condition
  • Forecast of the oil level:
    Prediction of the time until a critical oil level is reached due to a decrease or increase in the fill level (e.g. due to oil loss or oil contamination)
  • Determination of operating hours and idling times

4. data visualisation

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

  • Depending on the measured value, the limit values stored in the system either come from your specifications, from the gearbox design or are self-generated by the self-learning system within the first few months of operation.
  • If a limit value is exceeded, you are informed by the system and receive direct recommendations for action to solve your problem.
  • You can request the appropriate services for your industrial gearboxes at any time or directly after a system notification in the web application.

5. data connection (OPC UA)

Thanks to the standard implementation of an OPC UA interface, measurement data and status information can also be integrated directly into your customer system. A higher-level overall status ("Overall Health Status") and the raw data of the physical measured values are available.

The web application at a glance

In the DriveRadar® IoT Suite brings together and visualises all measured value results.

Device list


The device list provides you with an overview of the monitored industrial gear units in your system. The view can be freely configured with filter and grouping functions. A traffic light system simplifies continuous status monitoring and guarantees the user the necessary transparency regarding the gearbox status in an intuitively understandable way and at all times.

DriveRadar® IoT Suite / Device list view

Measured value overview and forecasts


With the help of the visualisation of the status and forecast values, you can see at a glance which measured values are OK or whether there is interference - all on one page.

  • Compact overview of all relevant measured variables
  • Vibration analysis and component localisation
  • Forecast of the service life of rolling bearings and gearing
  • Forecast of oil fill level and oil change
  • Quick access to contact and services
DriveRadar® IoT Suite / Measured value overview and forecast

Detailed view and recommendations for action


All historical data for a measured value is visualised in the detailed view. In the case of warnings and errors, you have the option of jumping directly to the trigger time.

  • The displayed recommendations for action help you to eliminate faults quickly.
  • If necessary, the corresponding services from SEW-EURODRIVE can be easily requested.
  • An export function is available for customised further processing of the displayed data.
DriveRadar® IoT Suite / Recommended action view

DriveRadar® IoT Suite web application


DriveRadar® IoT Suite different screens of the web application from desktop to smartphone

Our quotation at a glance

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

Gear unit monitoring

Cross section of industrial gear units

Your components

  • 2 × acceleration sensors
  • 1 × oil temperature sensor
  • 1 × ultrasonic sensor
  • 1 × speed sensor
  • 1 × DriveRadar® EdgeProcessingUnit
  • Optional: Integration of further measured variables

System monitoring

Industrial gearbox with motor with stylised view of the motor and graphical line elements

Your components

  • DriveRadar® DUV40A
  • Optional: Oil temperature measurement

Maintenance and servicing

DriveRadar® IoT Suite desktop view

Components of the cockpit

  • 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 across the entire product life cycle of one of our products

The app provides support from installation and startup to maintenance and fault diagnostics. TD and documentation are provided on a product-specific basis and as step-by-step instructions.

All applications monitored with DriveRadar® for industrial gearboxes are clearly visualised and all current measured values and associated limit values are displayed. In the event of status changes, the app provides immediate notification and initial recommendations for fault elimination.

Summarised:

- App for mobile devices including

- Automatic notification of errors and warnings

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

Our Experts are here for you!

Try it out 14 days free of charge our digital services and get access to our internally monitored industrial gearboxes. Talk to us and discover how our solution can optimize your processes.

Request now

Extended warranty "+24"
For industrial gear units

Have you decided in favour of our DriveRadar® IoT Suite monitoring system? Then order your industrial gearbox from the X.e series with factory oil filling and benefit from additional advantages.


Your advantages with +24 smart:

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


Downloads

Everything important at a glance

Download from Online Support:


To the DriveRadar® IoT Suite web application:

Let us advise you

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network, we are always there for you locally.

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