What's Condition Monitoring?

Condition monitoring is the process of monitoring a parameter of the condition in machinery (vibration, humidity, pressure, temperature etc.), in order to recognize a difference which suggests a developing fault. It is the key enabler of effective predictive maintenance.

With the unique benefit of discovering conditions that usually shorten normal lifespans, condition monitoring allows you to address these before they develop into a major failure. Condition monitoring techniques are normally used on rotating equipment, auxiliary systems and other machinery (compressors, pumps, electric motors, internal combustion engines, presses).

Thanks to the interaction of smart sensors, networking, wireless transmission and visualization, condition monitoring can be carried out not just continuously but from absolutely anywhere.

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Balluff Condition Monitoring Sensor

Excellency in the size of a thumb:
Flexible, smart condition monitoring packed into an extremely small space
vibration | contact temperature | relative humidity | ambient pressure

Imagine a sensor that monitors temperature, humidity, ambient pressure, and vibration at your machine and can detect errors at an early stage by using condition data. Condition monitoring is mostly based on machine learning to be able to carry out maintenance in real time to avoid unplanned downtime.
It also enables the Industrial Internet of Things (IIoT), allowing the conditions of machines, plants, and the associated components to be recorded, processed, and interpreted.

Features

  • ■
    Multiple, powerful sensing functions
    Four measurements possible in just one device: vibration, contact temperature, relative humidity, and ambient pressure.
  • ■
    Quick integration & easy to use
    Compact, but not complicated: robust stainless-steel housing (IP67 / IP69K) ideal for restricted spaces in harsh environments. Fast and simple configuration via IO-Link. Conforms to ISO 10816 for easy determination of the machine’s health status.
  • ■
    Smart pre-processing of data
    On-board data pre-processing for smart decision making without additional external processor.

BCM0002

BCM R15E-002-D100-01.5-S4


Vibration, contact temperature, relative humidity, ambient pressure

IP67

More about the product

Key features

  • Function

    Vibration velocity, vibration acceleration, vibration severity zone, contact temperature, relative humidity, ambient pressure, sensor self-awareness

  • Vibration, frequency range

    2...3200 Hz

  • Vibration, number of measuring axes

    3

  • Vibration velocity, measuring range RMS

    0…220 mm/s @79.4 Hz

  • Vibration acceleration, measuring range RMS

    0…16 g

  • Contact temperature, measuring range

    0…70 °C

  • Relative humidity, measuring range

    5…95 %rF

  • Ambient pressure, measuring range

    300…1100 hPa

  • Rated operating voltage Ue DC

    24 V

  • Interface

    IO-Link 1.1

  • Interface setting option

    Flexible process data configuration, vibration measurement based on ISO 10816-3, data preprocessing (statistics), events (pre-alarms and main alarms), delay times for alarms, search function with LED display (ping)

  • Connection

    Cable with connector, M12x1-Male, 3-pin, 1.5 m, PUR

  • Housing material

    Stainless steel (1.4404), membrane: ePTFE with nylon fleece

  • Protection degree

    IP67

  • Ambient temperature

    0...70 °C

Downloads

Recommended Accessories

BCM0001

BCM R15E-001-D100-01.5-S4


Vibration, contact temperature

IP67, IP68, IP69K

More about the product

Key features

  • Function

    Vibration velocity, vibration acceleration, vibration severity zone, contact temperature, sensor self-awareness

  • Vibration, frequency range

    2...3200 Hz

  • Vibration, number of measuring axes

    3

  • Vibration velocity, measuring range RMS

    0…220 mm/s @79.4 Hz

  • Vibration acceleration, measuring range RMS

    0…16 g

  • Contact temperature, measuring range

    0…70 °C

  • Rated operating voltage Ue DC

    24 V

  • Interface

    IO-Link 1.1

  • Interface setting option

    Flexible process data configuration, vibration measurement based on ISO 10816-3, data preprocessing (statistics), events (pre-alarms and main alarms), delay times for alarms, search function with LED display (ping)

  • Connection

    Cable with connector, M12x1-Male, 3-pin, 1.5 m, PUR

  • Housing material

    Stainless steel (1.4404)

  • Protection degree

    IP67, IP68, IP69K

  • Ambient temperature

    0...70 °C

Downloads

Recommended Accessories

  • Monitoring of decentralized pumps

    Hundreds of pumps supply your entire production: coolant supply, oil extraction and many more.Pump failure often leads to undesired and expensive production downtime.
    The difficulty is always keeping an eye on the condition of all pumps. Due to the distribution of the pumps throughout the production, it is not possible to carry out regular manual vibration measurements. Documenting the results is also time-consuming and certainly one of the unpopular tasks in everyday day’s work.
    So how about digitally and efficiently monitoring the process-critical pumps?
    You can do that with our BCM solution.
    Learn More >>

  • Efficient engine monitoring

    The entire production system only runs when all the motors are running smoothly. However, the loads on the different drives are sometimes higher than specified by the motor manufacturer. Knocking out the drive shaft or overheating the motor will reduce its performance. The result: an unplanned outage that involves effort and costs.
    A typical example is the overloading of conveyor belts. The more load carriers on the conveyor, the higher the efficiency of the production - until the engine fails. The Balluff BCM solution can prevent this. It is quick and easy to install, monitors temperature and vibration, and thus continuously provides information on the condition of the engine.
    Learn More >>

  • Keeping the industrial fans safe and secure

    Industrial fans play an extremely important role in the process and environmental preservation of ventilation in various places. However, as the operating time increases, the dust accumulated in the fans will unevenly adhere to the impeller. This gradually disrupts the dynamic balance of the turbine and causes a gradual increase in baring vibrations.
    The Balluff BCM sensor monitors such abnormal vibrations during turbine operation. Any abnormal vibrations are diagnosed and analyzed to grasp the full scope of the operating condition of the fans.
    Learn More >>

  • Overall temperature and humidity measurement in control cabinet

    Ambient room monitoring gives an overall assessment by measuring the temperature and humidity throughout the facility or in specific areas, where a certain temperature and humidity level is relevant. This is true for a control cabinet, where extremely high temperature levels can cause electronic failures.
    Furthermore, at low humidity levels, electrostatic discharge (ESD) is easily generated. ESD creates intermittent interference which can cause malfunctions in several production processes such as plastic and paper packaging or electronic production.
    Balluff’s BCM solution monitors ambient humidity, temperature and air-pressure for continuous room monitoring. Thus, corrective actions and changes to the room climate can be initiated at an early stage based on long term trends.
    Learn More >>

Balluff Condition Monitoring Solution

  • Monitor continuously

    Machine condition information
    is available anytime, anywhere

  • Easy to integrate

    Easy commissioning and
    configuration via IO-Link in your
    existing installation or independent

  • Save effort and costs

    Avoid unplanned plant downtimes
    and expensive production disruptions

Want more details?

Please download our BCM brochure for more details.