When it comes to increasing productivity and predicting system failures, there is no such thing as too much information. Voltage sensors continuously monitor the electrical state of industrial machinery, helping provide data insights on equipment health. That is why they are a critical component of condition-based maintenance (CBM).
Voltage sensors are one of the workhorses of CBM. Together with other monitoring technologies, they not only detect power anomalies but also help predict possible failures. Here’s how to use them as part of a broader monitoring strategy to bolster a condition-based or predictive maintenance program.
What is a voltage sensor?
Voltage sensors are devices that monitor voltage levels within equipment electrical systems by either detecting magnetic fields created by electric currents or by measuring voltage across a known resistance. They are sophisticated devices that serve as the nervous system of electrical equipment, monitoring voltage levels and turning that information into maintenance data that delivers insights about equipment health.
They can track both AC (alternating current) and DC (direct current) voltages, even in high-power systems. These days it’s crucial to use these sensors because their ability to spot small changes in electricity flow keeps equipment running smoothly.
As far as your CBM goals, voltage sensors are particularly helpful for:
- Detecting problems early on
2. Optimizing asset performance
3. Monitoring for excessive energy usage
4. Enhancing operator and workplace safety
With a steady flow of condition data, your team can switch from a reactive strategy to a proactive one. By detecting problems with power quality, breakdowns in insulation, or even motor malfunctions, teams can resolve them before they escalate into failures.
One of many tools in your CBM toolbox
Combining the data gathered by voltage sensors with that flowing in from other IoT technology, temperature sensors, pressure sensors, and more within a platform such as a Computerized Maintenance Management System (CMMS) provides a full picture of system health. Getting data in real time helps teams automate alerts, start work orders immediately, and create more accurate predictive algorithms. This aligns well with CBM’s goal of allocating resources and optimizing maintenance schedules more effectively.
As technology develops, voltage sensors are playing an increasingly integral role in the integrity of manufacturing operations. Because of the immediate data they provide, they help form the backbone of data-driven maintenance strategies.
Types of voltage sensors
There are all kinds of AC/DC and other voltage detectors to suit many different applications. All of these sensors play a part in an effective and comprehensive condition-based maintenance program.
Current monitoring sensors
Current sensors are key to checking electrical systems. AC current sensors track power that changes direction constantly, like in your home outlets, transformers, or factories. DC current sensors watch steady, one-way power flow, important for batteries and solar panels. Together, they help keep powered assets running smoothly by monitoring the direction and flow – or lack thereof – of electrical currents.
Voltage sensors
While there is some overlap, not all current sensors are voltage sensors but they work together in CBM. Measuring voltage helps monitor power and prevents overloading. In motors, unusual changes in voltage measurements can signal mechanical problems, like worn bearings or misalignment, before they cause noticeable issues or system failures.
Hall effect sensors
Hall effect sensors work by detecting magnetic fields created by the flow of electricity. They can measure power without direct contact, making them safe for high-voltage areas. These sensors can check DC power flow without disrupting the circuit, which is why they are popular in cars and factories.
Voltage dividers and transducers
Voltage dividers are like volume knobs for electricity, turning high voltages into smaller, safer amounts you can measure. Transducers and converters change voltage readings into signals that computers and control systems can understand. Together, they help teams safely measure and use information about electrical systems within equipment.
By selecting the right connectors and sensors, maintenance teams can improve the performance of CBM programs. When choosing sensors, consider several factors, including voltage range, accuracy level, and environmental conditions.
Applications of voltage sensors in CBM
Voltage sensors play important roles in various CBM applications:
- Temperature Management: Monitoring voltage across components helps maintain optimal temperatures, supporting effective temperature control and preventing overheating and efficiency loss.
- Capacity Planning: Voltage sensors help facilities monitor power supply distribution across circuits and equipment, allowing teams to plan for future capacity needs.
- Fault Detection: By analyzing voltage patterns in conductors and other components, sensors can spot early signs of electrical faults before major failures occur.
- Power Quality Checks: Voltage sensors spot ‘dirty’ power and AC voltage issues that can harm equipment or waste energy, helping keep electrical systems clean and efficient.
- High Voltage Systems: Specialized sensors, sometimes used with adapters, handle extreme voltages in power grids and industrial processes, ensuring safety and stability.
The versatility of voltage sensors in CBM can go well beyond these applications, with their data forming the foundation for predictive maintenance algorithms and assessments of equipment health.
Implementing voltage sensors in your CBM program
Using voltage sensors in your condition-based maintenance strategy requires a thoughtful approach to maximize their potential.
Integration with a CMMS
Perhaps the most crucial action you can take is to connect voltage sensors to a Computerized Maintenance Management System (CMMS). Uniting these two systems puts the most current health information about your machinery at your fingertips and enables automated work orders, among other things. Most CMMS software can integrate data and handle large amounts of information within a user-friendly interface for maintenance teams.
Software for predictive analysis
Use dedicated predictive maintenance software to interpret voltage readings. These programs can spot unusual patterns that might indicate trouble on the horizon. By combining all your sensor data, you get a complete picture of how your equipment is performing. For example, the software might notice that voltage drops slightly before a motor overheats, giving you time to fix it before it breaks down.
Best practices for implementation
As with any system or technology implementation, teams benefit from following a few common best practices:
- Consider a pilot program with sensors on your most critical assets to gain more experience in applying and using them.
- Invest in training your maintenance teams to use and interpret sensor data.
- Regularly calibrate sensors and validate their accuracy to ensure reliable data.
- Develop clear protocols and SOPs for responding to any alerts from the sensors.
The future of voltage sensing in CBM
Voltage sensors, like other types of condition monitoring sensors, are the keys to a sophisticated maintenance program that goes beyond the transition from reactive to preventive. As industrial IoT evolves, maintenance programs will have the ability to become smarter, and more efficient, saving companies lots of money and many headaches.
To learn more about how the right tools can be applied to your maintenance program, and how a CMMS can be the platform that helps you pull them all together, contact us today!
