Endress+Hauser Deploys Multiple Types of Sensors to Improve Field Maintenance

Predictive maintenance has become a big deal in the world of field service and brands the world over are constantly searching for ways to improve their data collection methods and make their service provision more agile and proactive than their competitors.

Of course, the predictive maintenance journey always begins with sensors and it’s the quality of those sensors that can have the greatest impact on a brand’s ability to gather the data necessary for this type of field service, and therefore improve provision.

As a globally operating process and laboratory instrumentation and automation supplier with net sales of approximately €2.6 billion and net income of €254.9 million, Endress+Hauser has been at the fore of predictive maintenance since it was first conceived. The company also perpetually innovates when it comes to the sensors it deploys and sells, which make proactive field service provision possible.

Endress+Hauser

Two types of sensors supplied by Endress+Hauser are ultrasonic and radar-based level measurement tools that make sure any company dealing with solids, liquids and gasses that need to be maintained at a certain level can do so, without the need for manual checks or maintenance.

Ultrasonic sensors are an effective solution for liquids and bulk solids and are characterized by easy planning and assembly, fast and safe commissioning, a long service life and reduced maintenance costs. Meanwhile, radar sensors offer on-contact, maintenance-free measurement that is unaffected by medium properties such as density and conductivity, in bulk solids also unaffected by filling noise and dust, have a freely adjustable measuring range, and are suitable for use in extremely high temperatures up to +450°C/+842°F.

While radar level measurement has long been held as a best-in-class solution, Endress+Hauser makes the case that ultrasonic is actually preferable in certain situations and service providers should make sure they are deploying the best solution for the application in question.

"Radar technology is increasingly viewed as the best method of level measurement, but this isn’t necessarily true for every application," says Endress+Hauser in a blog post comparing the two. "Radar sensors have certainly made great advancements in performance, accuracy and even cost, but they are not a one-size-fits-all solution and should not be treated like one. Though radar is versatile, there are some applications where ultrasonic level technology is a better fit."

However, level measurement is not the only area of sensor-enabled predictive maintenance in which Endress+Hauser is innovating with a recent announcement regarding a new generation of liquid analysis sensors.

Liquid Analysis

In order to leverage Industry 4.0 technology to provide simple, safe, and connected liquid analysis, Endress+Hauser is phasing out older models of analogue liquid analysis sensors and replacing them with a digitally powered alternative, which can improve accuracy, ease calibration, simplify troubleshooting and reduce required maintenance.

"Memosens 2.0 sensors store numerous relevant data points, such as operating hours, minimum and maximum temperatures, measured values, calibration histories and load matrices," said the company in a press release. "All this data can be used and processed for comprehensive analysis and more precise process management. The sensors also provide a sound basis for predictive maintenance strategies when used in conjunction with Endress+Hauser’s Heartbeat Technology, along with enhanced [Industrial Internet of Things] services via the Netilion ecosystem."

The new sensors use non-contact digital data transmission which eliminates moisture, corrosion, and salt bridge effects. Instant messaging alerts field service technicians if signal transmission is disturbed by other factors and built-in galvanic isolation ensures accurate measurement in the presence of electromagnetic interference and other electrical noise. If the sensors need to be replaced in the field, lab-based pre-calibration and bayonet connection points mean downtime is significantly reduced, which is the overall goal of sensor-based predictive maintenance strategies.

"Memosens 2.0 combines cutting-edge technology with maximum practicability. Because the Memosens sensors are equipped with highly integrated electronics, they can be calibrated and adjusted under lab conditions that are favorable for the operator and stable for precise results," according to the Endress+Hauser blog. "Replacing sensors in the field is a simple process and can be performed in a timely manner thanks to the lockable bayonet connector and automatic sensor identification by the transmitter."

Final Thoughts

The case for predictive maintenance has been thoroughly and inarguably made and most field service brands are now deploying the practice or are in the process of their digital transformation. Our attention therefore turns to further developing the components and concepts that make predictive maintenance possible and further improve capabilities in this area.

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