Your machines are constantly communicating with you. They tell you how they are feeling, whether they are under stress, or if a problem is brewing. You just have to learn to understand their language. This is precisely the job of Condition Monitoring. It is the foundation of any predictive maintenance strategy.
Condition monitoring involves supervising the operational state of equipment by continuously measuring and analyzing physical parameters. The goal is clear: to detect problems early before they lead to costly failures. But which technique is right for your specific problem? Here is an overview of the five most important methods.
Every rotating machine generates a unique vibration pattern—its "heartbeat." If this pattern changes, something is wrong. Vibration analysis is the most widely used technique for monitoring motors, pumps, fans, and gearboxes.
What it detects: Imbalance, misalignment, bearing defects, gear problems, loose parts.
How it works: Accelerometers are placed at strategic points on the machine. They measure vibrations in frequency and amplitude. Software analyzes this data (often using FFT analysis) and compares it to the "healthy" reference pattern.
Ideal for: All types of rotating machinery. It is the best method for the early detection of mechanical wear.
Where friction, electrical faults, or wear occur, excessive heat is often generated. Thermography makes these temperature differences visible and is a powerful, non-contact tool for maintenance.
What it detects: Overheated bearings, faulty electrical connections in cabinets, insulation defects, clogged cooling systems.
How it works: An infrared camera creates a thermal image (thermogram) of the equipment. "Hot spots" indicate potential problems. Inspections can be performed during operation and from a safe distance.
Ideal for: Electrical inspections (cabinets, motors), checking bearings and gearboxes, detecting leaks in steam or compressed air systems.
The oil in a machine is like the blood in the human body. Its analysis provides deep insight into the health of the equipment. Oil analysis is crucial for hydraulic systems, large gearboxes, and turbines.
What it detects: Wear particles from metals (showing which component is wearing), contaminants (water, dust), degradation of lubricating properties.
How it works: Small oil samples are taken at regular intervals and analyzed in a lab. The results show changes in the chemical composition and the presence of foreign particles.
Ideal for: Assets with large oil volumes such as hydraulic presses, turbines, compressors, and large gearboxes.
Many mechanical and electrical problems generate sounds in a frequency range that is inaudible to the human ear. Ultrasonic testing converts these high-frequency signals into audible sounds or visual data.
What it detects: Leaks in compressed air and vacuum systems (the hissing sound), electrical partial discharges (tracking, corona), incipient bearing damage (high-frequency friction).
How it works: An ultrasonic detector captures the high-frequency waves and makes them perceptible to the inspector. It is a very versatile and easy-to-learn technique.
Ideal for: Detecting expensive compressed air leaks, electrical safety inspections, and early warning of bearing damage, often before it becomes visible in vibration analysis.
This electrical testing method assesses the health of a motor's entire electrical system (from the terminals through the cables to the windings and rotor) without having to disassemble it.
What it detects: Winding issues, rotor faults, poor connections, ground faults.
How it works: Test devices send low-voltage signals through the motor and analyze the response to assess its electrical health. The test can be performed while the motor is de-energized.
Ideal for: Checking the health of critical electric motors to prevent electrical failures.
There is no single "best" condition monitoring technique. The strongest strategy often combines several methods. With a flexible low-code platform, you can bring together the data from all these different sources. Visualize vibration data alongside the results of oil analysis and the thermal images from your thermography rounds. This way, you create a comprehensive health profile of your assets and make informed decisions that transform your maintenance from a reactive fire department into a proactive value driver. Find out more about machine data and IoT in subsequent blog articles (check out the Heisenware Blog).