The market for vacuum pumps has witnessed a continued demand, owing to large-scale applications within the plastic industry for degassing and vapor extraction. The pumps, often placed in concealed locations, experience failure at unexpected times, leading to disruption in operations, content redirection, besides delay in shipment to the market. The pressure, thermal and vibratory conditions are early indicators of the need for maintenance, and 60 percent of incidents boil down to filter and oil problems.
Leading vendors such as Wittmann, AEC, Una-Dyn, and Conair have introduced quality smart vacuum pumps such as MachineSense’s Vacuum pump analyzer, featuring the concept of active monitoring and diagnosis. The vacuum analyzer, coupled with the cloud-based application branded as Crystalball Analysis, transmits real-time data such as system pressure, temperature, and vibrations through sensors housed within the vacuum pump to the backend server. Besides, patented prognosis and automatic 24/7 remote monitoring, the system prevents most of the occurrences of disruptions in terms of time wastage for isolating root problems, maintenance downtime, and likely solution, besides cutting down unplanned visits by a technician.
The information related to components of the vacuum pump such as bearing and belt condition, besides details such as pressure, pump utilization, oil level, and filter status, transmits to the data center and mapped on smart devices. The constant comparison of the system’s health against ideal operations detects a deviation from normal in real-time and displays alerts on the screen in form of red identifying immediate maintenance required, yellow as a warning, and green as normal operation. Besides quick installation, hardly takes half an hour that includes sensor placement on the pump, connecting to a data center, fasten pressure sensor, and online registration, The system features early detection, freedom from frequent maintenance, alerts in case of non-conformance.
The pump analyzer boasts of being pocket-friendly, costing just $999 that includes six months of free data plan, a lot less compared to the cost, running in thousands of dollars, incurred in absence of such solutions. Besides, the system boasts of monitoring two pumps at a time from a single data center and cutting down maintenance costs.