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SOLUTION

Industry Solutions

Solution of Reducer Fault Prediction System

Problems In Reducer equipment

In the reducer rotating equipment industry, the industrial chain consists of reducer manufacturers, OEMs and end users. Generally, reducer manufacturers hope to solve problems related to after-sales operation and maintenance efficiency, maintenance costs, and product market application performance. The reducer OEM hopes to solve the problems related to the maintenance cost of the core components of the host equipment and the operational health of the on-site host equipment. End users hope to solve problems related to downtime and production, real-time operation of equipment, and potential dangers to personal safety caused by abnormal equipment production.

Solution Value

According to the problems encountered in the reducer industry,Witium launched the "reducer fault prediction system solution", which carries out the health status analysis and early warning fault analysis of the reducer and host equipment for the monitoring of the reducer operation status on the user's site, forms a professional reducer fault prediction and health diagnosis report, and gives maintenance suggestions. Witium 's reducer fault prediction solution brings great commercial value to users:

Solution Details

Solution Architecture

  The reducer fault prediction solution uses the high-frequency vibration sensor of the Internet of things to collect the vibration waveform samples and surface temperature of the equipment, and generate the vibration characteristic samples of the reducer equipment; The edge computing gateway collects the three-phase winding temperature and lubricating oil temperature of the reducer through the platinum resistance to understand the operating load state of the reducer. Combined with the vibration characteristics of the sensor, the intelligent mechanism model algorithm is used to analyze the big data of the sampled data, so as to realize the prediction of reducer equipment faults such as imbalance, misalignment, looseness, gear wear and bearing aging; Then upload the data samples and analysis learning results to the witcloud Internet of things data cloud platform through mqtt; The SaaS business cloud platform of the solution provides users with status monitoring, scene monitoring, fault management, operation and maintenance management, equipment management, customer management, authority management and other functions; It also provides data interface function to facilitate users to import equipment status into intelligent factory operation and maintenance platform system. At the same time, through big data analysis tools, the business cloud platform provides professional users with operation status analysis and early warning fault analysis of reducer equipment, and forms professional reducer equipment health diagnosis reports and maintenance suggestions.

Solution Software

Solution Web Side Software Diagram

Solution Mobile Software Diagram

Solution Hardware

High frequency vibration sensor

MEMS vibration sensor
Medium and high frequency vibration monitoring
The sampling frequency is up to 20khz
Magnetic suction easy installation

RS485
WTS4VXX

USB
WTS6VXX

BASIC PARAMETER
  • Power Input
    DC4.5V-5.5V
  • Low power function
    support
  • Work Temperature
    -40 ℃-105 ℃
  • Work Humidity
    10%-95%(No condensation)
  • IP Rate
    IP67
  • Installation
    Threaded fixing / magnet fixing
  • Overall dimension
    40*40*15mm/40*40*19mm
  • COM Interface
    RS485/USB
  • COM Protocol
    Modbus-RTU
  • Shell Materials
    Aluminum
TEMPERATURE
SENSOR
  • Temperature Object
    Interface temp
  • Temperature Range
    -40°C~105°C
  • Resolving power
    ±1°C
VIBRATION SENSOR
  • Acceleration(G)
    3 Axis:±8g
  • Sample Duration
    1S/10S
  • Frequency
    4KHz/20KHz
  • Axis
    3 Axis
  • Acquisition accuracy
    1mg/LSB
  • Data Content
    Real-time vibration wave/ Characteristic Value

Edge computing gateway

Edge AI Calculation
Several vibrating channels
Multiple wireless Transmit
Embedded algorithm model

WTG9XXW

WTG9XXF

WIRELESS COMMUNICATION
PARAMETER
  • Communication
    WiFi
    4G(Cat1)
  • Mbps
    3Mbps

    upstream 5Mbps/
    down 10Mbps

  • Work Method
    Sta mode / AP configuration
    -
  • DTE-DTE
    40M
    -
  • communication channel
    802.11b/g/n
    LTE-TDD:B38/B39/B40/B41
MAIN PARAMETER
  • Number of vibration channels
    1-6 Optional Channels
  • Vibration interface
    RS485(ModBus-RTU)
  • Oil Temperature
    1 Pt100 Breakage Detection
  • Three winding temperature
    3 Pt100 Breakage Detection
  • LED
    1 * power light, 1 * sensor communication light, 1 * network status light
  • Firmware update
    Online update, remote update
BASIC PARAMETER
  • Shell Materials
    Industrial plastic shell
  • Overall dimension
    115*70*47mm
  • Installation
    Industrial guide rail / strong magnetic fixing / flange fastening / Strap
  • Power Input
    85-262VAC/12-36VDC
  • Operating temperature
    -30~70°C
  • Storage temperature
    -40~85°C
  • Protection
    Overload protection / output short circuit protection / overheating protection
  • Waterproof grade
    IP67

Solution Hardware Diagram

Site Map Of Successful Cases

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Copyright: Shanghai Witium Information Technology Co., Ltd
Website records: Shanghai ICP 19015228-1
Police record number: 31011202009248