Condition Monitoring

Condition Monitoring of Machines and Systems

The term condition monitoring refers to the process of monitoring a parameter of conditions in machines and systems. Nowadays, "listening" to motors, electronic devices or areas of a system to check for faults goes far beyond on-site inspections by workers.

Cloud on premises for Condition Monitoring

Figure 1: Condition Monitoring within a Private Cloud (click to enlarge)

Thanks to state-of-the-art sensor technology, intelligent field devices and wireless transmission, condition monitoring can be carried out not just continuously but from absolutely anywhere. On the basis of the collected data, systems can indicate an imminent failure at an early stage. Reliable condition monitoring is therefore essential for predictive maintenance.

Simplify condition monitoring of your plant using products from Turck – from sturdy sensors to system solutions with flexible cloud monitoring. Whether the system is in a new build or you want to retrofit the solutions you have in an existing environment – all devices can be easily integrated into your existing automation system. Alternatively, decentralized standalone systems can monitor key condition data without affecting the main control unit.

Cloud Solutions for Condition Monitoring

Figure 2: Condition Monitoring within a Public Cloud (click to enlarge)

The images show how you can implement an effective condition monitoring process. The cloud service is structured in two ways: The cloud can either be hosted on the company's own server (Figure 1), or it can function as a public cloud hosted in Turck's data center (Figure 2).

Key Technologies for Condition Monitoring

Condition monitoring can be carried out in a practical and reliable manner if suitable key technologies such as IO-Link, multiprotocol Ethernet, wireless signal transmission or cloud solutions are used.

Wireless Signal Transmission

Need to check the readings from machines that are difficult to access, or simply want to avoid wasting time with complicated wiring? Then use the DX80 wireless system for a convenient way of wirelessly transmitting condition data from the field within a proprietary wireless network. Many of the sensors in Turck's product range can be seamlessly connected to the transmitter modules, and can also be run on batteries if required.

Condition Monitoring with IO Link

IO-Link

The IO-Link communication standard not only makes it easier to install devices, but it also enables a greater variety of data to be sent between the controller and the field level. IO-Link devices provide additional information acyclically, such as parameters or diagnostics messages. Maintenance engineers can use these to detect irregularities earlier and analyze errors more effectively. Turck offers you an extensive portfolio of IO-Link solutions.

Cloud Solutions

Monitoring condition data 24/7 and from any end device, configuring personalized dashboards, receiving information about critical values automatically — you can do all this and more with Turck Cloud Solutions. The TCG20 cloud gateway encrypts data and sends it to the Turck cloud, or to online services such as Amazon Web Services or Microsoft Azure. Alternatively, the Turck cloud can also be hosted directly on a company's own server (on premises).

Multiprotocol Ethernet

Turck's I/O modules can work in parallel in different Ethernet protocols, allowing condition monitoring to be carried out separately from the cyclic process communication. Measurement data is transferred to the main control unit via PROFINET, for example, while status data is transmitted acyclically to another PLC via Modbus TCP.

Condition Monitoring with Multiprotocol Ethernet

Increased availability of machines and systems

  • Continuously monitoring the condition of machines and systems forms the basis for predictive maintenance
  • Effective monitoring systems and automatic notifications allow workers to respond faster when thresholds are exceeded
  • Operators can carry out specific fault analyses using diagnostic data or by saving maximum values

Improving economic efficiency of maintenance

  • Remote monitoring replaces the complex and error-prone process of carrying out presence checks
  • Operators can plan maintenance work more efficiently using condition data from specific machines

Convenient retrofitting

  • Condition monitoring is carried out using easy-to-install sensors and battery-powered wireless modules
  • Condition monitoring can operate as a standalone system if required, regardless of the existing network architecture

Condition Monitoring Products

Follow these links to our product database and find the right product for your Condition Monitoring solution.

TBEN-PLC – Block I/Os with CODESYS 3 PLC

User benefits: Distributed intelligence with simple integration for control tasks directly on the machine or plant


TBEN – Multiprotocol Ethernet I/O solutions in IP67

User benefits: Easy integration into systems and diagnostic functions via integrated web servers also on smartphones


ARGEE – PLC functionality for multiprotocol I/O modules

User benefits: Programming of basic functions without any knowledge of a programming language made simple


TCG20 – Cloud Gateways with Wi-Fi and UMTS

User benefits: Simple integration into automation networks, secure communication with End-to-end encryption, pre-process data without additional software


Industrial Wireless Radios

User benefits: Use the DX80 wireless system for fast and safe transmission of process data from the field to higher level control systems


Wireless Sensors, Lighting & Indicators

User benefits: Connect Sensors and displays to the DX80 wireless system and transmit condition data across a proprietary network


IO-Link Products

User benefits: Fast device replacement, flexible and reliable application through comprehensive configuration and diagnostic options


TX – Programmable HMI

User benefits: Monitor sensor and machine data and control automation processes – with brilliant graphics and resistive touch.


IM(X)12-CCM – Condition monitoring for control cabinets

User benefits: Recognizes potential sources of error for preventive maintenance, thus avoiding unplanned shutdowns


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