Condition Monitoring

Leakage Detection (Air) Sensors detect air leaks in compressed air systems and machinery. Continuous monitoring enables the localization of losses and the initiation of targeted measures. Leakage Detection (Gas) Sensors identify gas leaks in pipelines and systems. Permanent monitoring supports safe operation and reduces unplanned downtime. Leakage Detection (Water) Sensors detect water escaping from systems and pipelines. Deviations in water flow are identified early to prevent damage and downtime. In energy monitoring, leak detection makes energy waste visible; in maintenance, leaks are detected early, located and sealed in a targeted way.

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Partners who have already successfully implemented this use case

Making hidden problems visible. Sensors monitor bolts and connections for wear, loosening or defects. Problems are detected before they cause greater damage: in condition monitoring and predictive maintenance there is time to retighten or replace, and in corrective maintenance defective connections are identified and replaced in a targeted way. This increases operational safety.

Implemented under NDA – user company confidential

Detecting anomalies through sound patterns. Acoustic sensors diagnose wear and malfunctions in machines based on their sound patterns. In condition monitoring they show the machine state continuously, in predictive maintenance they make maintenance plannable, and in corrective maintenance they locate defects for targeted repairs. This reduces unplanned downtime and consequential damage.

Partners who have already successfully implemented this use case

Digital systems for tension and thrust force monitoring detect mechanical anomalies and overloads early to prevent downtime and damage. Integrated into machine controls, they enable immediate responses, protecting processes and assets. If an overload does occur, the affected components can be located and repaired in a targeted way.

Partners who have already successfully implemented this use case

Precise diagnostics through vibration analysis. Monitoring bearings or heat treatment furnaces provides early warning signals for mechanical irregularities or temperature deviations. In condition monitoring and predictive maintenance this ensures production quality and prevents damage; in corrective maintenance faulty bearings are located quickly and repaired in a targeted way.

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Partners who have already successfully implemented this use case

Detect damage before it gets costly. Breaks or cable stress often occur unexpectedly – with serious consequences for production and asset availability. Break detection systems continuously monitor critical movements and report the smallest deviations in real time. In condition monitoring and predictive maintenance this enables targeted maintenance planning; in corrective maintenance repairs start without searching for the cause.

Partners who have already successfully implemented this use case

Centralized collection of distributed measurement and status data. Remote reading enables the automated retrieval of operational, status and consumption data from systems and infrastructure without manual on-site reading. The data feeds into condition monitoring and energy monitoring and is documented digitally without gaps at the same time.

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Partners who have already successfully implemented this use case

Cable and chain monitoring detects breaks, abrasion and structural changes in cables and chain links based on movement anomalies and physical measurements. Monitored parameters include tensile and compressive forces, bending radii, insulation resistance, temperature, current and vibration events. This makes maintenance plannable, and defective links or sections can be located and replaced in a targeted way.

Partners who have already successfully implemented this use case

With modern sensor technology and smart data analysis, damage can be detected before it escalates. Whether leaks in water pipes, overheating in electrical systems or mechanical wear – continuous monitoring makes problems visible early. In condition monitoring and predictive maintenance this leaves time for targeted maintenance, in corrective maintenance affected components are located quickly, and in loss prevention it protects assets and infrastructure in the long term.

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Partners who have already successfully implemented this use case

Efficiency in warehouse and production. Real-time monitoring of fill levels in tanks or silos enables precise control of production processes. Automatic notifications make reordering easier and prevent overflows or bottlenecks. In asset management inventories stay in view, and the readings are logged automatically – a reliable basis for audits and analyses.

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Partners who have already successfully implemented this use case

Digital temperature monitoring, even for extreme conditions. In our network, IoT-based temperature measurements are implemented for steam pipes, for example – using LoRaWAN or mioty® sensors that operate maintenance-free for over 10 years. In condition monitoring and predictive maintenance the data reveals trends and anomalies early; in corrective maintenance it helps locate hotspots and repair defective components in a targeted way.

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Partners who have already successfully implemented this use case

Tool wear leads to quality fluctuations and increased scrap in many operations. Many companies use vibration and force sensors that capture wear conditions in real time and enable timely replacement.

Partners who have already successfully implemented this use case

Sensor technology for gas and pollutant detection (e.g. CO₂, NOx, CH₄, VOC) monitors emissions continuously. In condition monitoring it secures operations and compliance, in energy monitoring it provides emissions data for reporting and ESG, and for employee safety it gives early warning of pollutant exposure. When gas or pollutant leaks occur, the affected components can be repaired in a targeted way.

Partners who have already successfully implemented this use case

Precise level measurement without maintenance effort. Battery-powered sensors record groundwater levels automatically – even in hard-to-reach areas. The maintenance-free technology delivers reliable data for condition monitoring and predictive maintenance. When levels deviate, the cause can be located and faulty sensors or pipes repaired in a targeted way.

Partners who have already successfully implemented this use case

Humidity measurement captures ambient conditions in the form of relative humidity and its changes over defined periods. This makes it possible to monitor air conditions even in hard-to-reach or non-visible locations. In condition monitoring and predictive maintenance the data reveals trends early; in corrective maintenance it helps diagnose deviations and locate affected spots.

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Partners who have already successfully implemented this use case

Efficient maintenance of filter systems. Sensors capture the status of filter mats as well as condition and wear data from pumps and fans. In condition monitoring and predictive maintenance this makes it possible to predict maintenance needs and plan service calls proactively. In corrective maintenance, defective filters, pumps or fans are located quickly and replaced in a targeted way.

Partners who have already successfully implemented this use case

An unstable gas flow can significantly affect the quality of coating or melting processes, for example. IoT-based monitoring systems analyze gas pressure and flow in real time and regulate them dynamically to ensure uniform material distribution and optimal process conditions. In energy monitoring, the data also shows where gas is consumed unnecessarily.

Implemented under NDA – user company confidential

Transparency over production performance and runtimes. By capturing pulse counts, cycle times, utilization, and throughput directly at the machine, production processes become continuously measurable. The resulting data provides a reliable basis for analyzing runtimes, downtimes, and performance deviations of individual assets or production lines.

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Partners who have already successfully implemented this use case