The world of industrial automation is all about continuity and reliability. Unplanned machine downtime can lead to high maintenance costs, lost production and reduced product quality. At Gerbin Control, we see that predictive maintenance, also known as predictive maintenance or PdM, is increasingly the key to increasing reliability. By applying smart sensors and advanced data analytics in our control cabinets, we help maintenance engineers and plant managers predict failures before they occur.
Table of Contents
What is predictive maintenance?
Predictive maintenance is a maintenance strategy that monitors the actual condition of a machine. The goal is to perform maintenance at exactly the right time. Instead of standard preventive maintenance at fixed intervals, we continuously measure parameters such as vibration, temperature, humidity and load. This data provides insight into wear, bearing defects or other abnormalities that can lead to failures. The result is extended plant life, higher productivity and lower maintenance costs.
Sensors and measurement points in control cabinets
An effective PdM solution starts with the right sensor technology. In our control cabinets we integrate, among others:
- Vibration sensors Which detect imbalance, wear or damaged bearings
- Temperature sensors that signal overheating of drives, motors or electrical components
- Humidity sensors Which detect condensation or leaks
- IO-Link-compatible sensors that provide fast and reliable data transfer to the IIoT network
These sensors are strategically placed on critical components such as pumps, gearboxes and motors. The signals enter the control cabinet’s IIoT control system. There, they are processed by an integrated PLC and forwarded to the chosen cloud platform or local machine monitoring software.
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AI and machine learning for fault detection
The real benefit of predictive maintenance becomes apparent when raw sensor data is turned into actionable insights. At Gerbin Control, we combine machine learning and trend monitoring to recognize patterns in vibration measurements, temperature fluctuations and other process data.
With techniques such as vibration analysis and spectrum analysis, we can detect abnormalities that remain invisible to the human eye. Examples include incipient bearing damage or a slight imbalance in a drive. These analyses follow international standards such as ISO 10816 for vibration levels. This ensures an objective and reliable assessment.
ROI and practice case
In a production environment with multiple packaging lines, we implemented a predictive maintenance solution in the existing control cabinets. Using vibration meters, temperature sensors and moisture monitoring, impending failures could be detected at an early stage.
Results:
- Unplanned downtime reduced by 35 percent
- Maintenance costs reduced by 20 percent through targeted interventions
- Life of bearings and drives extended by 18 percent on average
The investment in PdM was recouped within fourteen months, mainly because costly production stops were avoided.
Contact our experienced innovator
Cees Brasser
With more than 26 years of experience at the helm of Gerbin Control, Cees Brasser is your expert on panel construction for the machinery sector. Discover how his knowledge and insight can take your project to new heights. Get in touch now!
Tips for implementation
For successful implementation of predictive maintenance in control cabinets, we recommend:
- Start with critical machines in the machine shop
- Choose sensors that fit the application and measurement range
- Ensure reliable connectivity via PROFINET or Modbus TCP
- Use cloud monitoring or local analytics software for trend analysis
- Train operators and maintenance staff to work with the data
At Gerbin Control, we integrate predictive maintenance technology directly into our panel construction projects. Thus, we not only provide reliable control solutions but also a complete condition monitoring system. With this, we prevent downtime, increase safety and optimize the efficiency of the production process.
Want to know how predictive maintenance can improve your business continuity? Contact our engineers for tailored advice.
