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Condition monitoring with intelligent drives

Aerial view of Nordhavn in Copenhagen, with a condition-based monitoring signal showing on top of several buildings

Drives are more than simple power processors

With the ability to act as sensors and sensor hubs, to process, store and analyze data, along with connectivity capabilities, drives are vital elements in modern automation systems and building management systems (BMS). Integrated condition-based monitoring functionality enables new ways of performing maintenance, such as condition-based maintenance.

Evolution of Industrial Automation Systems

In the transition to the current millennium, we have witnessed a profound change in technology, which has led to a whole new way of working in a digital world. This is the fourth industrial revolution. The first industrial revolution, which occurred during the 18th and 19th century, was a mechanical revolution, triggered by the invention of the steam engine. By the end of the 19th and early 20th century, the second industrial revolution unfolded with the adoption of mass production, electrification, and changes in communication. This period is also referred to as the Electrical Revolution. Later in the 20th century, the third industrial revolution brought advances in semiconductors, computing, automation and the internet. This phase is also known as the Digital Revolution.

The fourth industrial revolution has emerged as a result of networking computers, people, and devices fueled by data and machine learning. Although the term “Industry 4.0” is quite vague, a possible definition for Industry 4.0 describes the intelligent networking of people, devices, and systems by utilizing all possibilities of digitalization across the entire value chain.

Trends in Industry 4.0 Automation Systems

The impact of Industry 4.0 on motor systems and building management systems is a migration from the “automation pyramid” to “networked systems”. This means that the various elements of the system, such as motors, drives, sensors and controls, are interconnected and connected to a cloud - a data center where data is stored, processed, analyzed, and decisions are made.

In an automation network, the amount of data is prominent. As data is mainly produced by sensors, the number of sensors in modern automation systems is increasing. Motors and driven machines such as fans, pumps and conveyors are not the most obvious participants in a data network. Sensors are therefore required to collect data from these machines. The sensors are connected to the data network using various means to utilize the data. During the introduction of an advanced condition monitoring system, the additional cost of sensors and connectivity is often seen as a barrier.

Modern variable speed drives open new opportunities in the Industry 4.0 automation network and in building management systems. Traditionally, drives have been considered power processors for controlling the motor, fan, conveyor and/or pump speed. Today, drives are also part of the information chain, using the advantage of built-in processing power, storage capacity, and communication interface, within the drive.

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