Condition Monitoring in the Automotive Industry

Condition monitoring is the process that considers parameters of the condition in the machine (vibration, temperature, etc.) to identify a notable change in the condition which is an indication of a developing fault. 

Condition Monitoring is a maintenance approach that monitors the actual condition of equipment, extracting information to know the actual wear and tear, degradation, and if a significant change has occurred. The data collected is used to establish trends, predict failure, and calculate the remaining life of an asset.

Predictive maintenance helps to determine the condition of running equipment. It estimates the maintenance requirement and schedule.

The maintenance engineer’s job is to prevent any disruption in the manufacturing process. With help of predictive maintenance, the maintenance team can plan effectively for the replacement timeline and make the necessary workarounds until new equipment is installed.

Improving uptime, reliability, performance, and safety are the top priorities for industries and businesses today. Industries are focusing on efforts and resources on controlling costs and maximizing value from existing investments.

Condition Monitoring in the Automotive Industry

Benefits of condition-based monitoring

  • Reduction in downtime
  • Improvement in productivity
  • Reduction in spares inventory
  • Reduction in consumables
  • Remote monitoring

Recently, the automotive industry has faced many challenges which include declining sales, global political uncertainty, CO2 penalties, and rapidly changing customer demand, global pandemic since 2019.

With new features, the advancement of technologies, expectations of customers are on the rise. To maximize the profits of the industry, the manufacturers have to design and produce the products in as much variety as possible to furnish the demands of the customers. Thus, there is a challenge for industries to manufacture products of the right quality and quantity, at the right time at minimum cost for their survival and growth. 

Common challenges to the automotive industry

  • Dependency on human expertise

Most manufacturing operations are still dependent on human experienced decisions

  • Globalization

The globalization of the automotive industry leads to an increase in vehicle and parts imports from other countries. It is impacting the economic well-being positively and negatively. 

  • Competitive pressure 

With new emerging innovations, there is cut-throat competition. There are more choices than ever

  • Shifting market conditions

Digitization, increasing automation, and new business models, the rise of new technologies, are dramatically changing the market condition.

  • Consumer Buying Trends 

Increasing consumer awareness, the trend of buying pre-owned cars, the car is losing its relevance as a status symbol, but it is gaining more relevance as a solution based on user experience, interest-based on digital features

  • Cost pressure

Automotive manufacturers pass tough improvement targets on to their suppliers of parts and components, the companies striving to meet constantly changing demands. Better design of logistics chains, higher productivity in production, lower labor cost are few examples of adjustments that are demanded of suppliers.

Improving reliability, performance, and safety are among the top priorities for industrial organizations and businesses today. They are focusing efforts and resources on controlling costs and maximizing value from existing investments.

Automotive production facilities can implement this uninterrupted, real-time condition monitoring to automate measurement taking and alert of trending situations. It eliminates the task of tedious manual review of each device, freeing up the maintenance team to attend to other important tasks.

Smart sensors mounted on machines sense the real-time mechanical parameters like vibrations, temperature, and acoustics from the machine. Most of all the probable conditions that are likely to cause equipment damage or failures, can be captured by smart sensors on these machines. Vibration analysis is the most promising diagnostic tool based on condition-based monitoring, for which smart sensors can be employed.

Enabling predictive maintenance in the automotive industry

Predictive maintenance can help in adjusting maintenance intervals and help in the precise prediction of future failures along with diagnosing already existing ones.

Implementation of Sensors, Smart devices 

The Industrial Internet of Things (IIoT) made it possible for machines to talk. Smart sensors communicate wirelessly with you. It collects the data from machines and modern technologies make use of this data to improve maintenance processes and improves plant efficiency.

Software analytics

New smart sensors are equipped with software data analytics mobile apps and a convenient dashboard. Now the user can configure the sensor easily and have all the data at fingertips.

Alerts and notifications

The smart sensor sends alerts and notifications as soon as it detects the changes in the machinery’s health.

Machines that can be monitored

The sensors can monitor any rotating equipment like motors, fans, bearings, gearboxes, pumps, spindles, and generators. Most of the machines used in the automotive industry can be monitored using these smart sensors.

The equipment used in the automotive industry like stamping press, forging press, trimming press, drawbench assembly, die casting machines, fin pass mill, dowel milling machine, gear-hobbing machine, and the list goes on.

For predictive maintenance, there are multiple solutions in the market. Infinite Uptime is one of the best one-stop solutions for the smart sensor.

Infinite Uptime is a global industrial edge solution provider for mechanical predictive maintenance in the engineering and process industries.

Infinite Uptime’s Industrial Data Enabler (IDE), patented edge-computing Vibration monitoring system for predictive analytics and maintenance remotely gathers tri-axial vibrations, noise, and temperature of any mechanical rotating equipment in real-time. It empowers the Maintenance team to monitor the machine uptime, reduce unplanned downtime, and combat impending equipment damage in advance. Moreover, the end-to-end solution with visual indicators ensures maximum machine-availability, decreased inventory of spares and maintenance costs, and complies with the guidelines on safety and physical distancing directed by the Government.  Not only does it help reduce maintenance fixed costs at a time where a reduction in costs and manpower is a dire need, but it also enhances social distancing by allowing remote monitoring of a plant without physical intervention.

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