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Industries and Solutions

Condition Monitoring

Continuously monitor the condition of machines, plants and processes

Stop guessing, start knowing

Condition monitoring systems and their components contribute to the efficient and trouble-free operation of machines and plants. With them, you know the current status and can make informed decisions for the future - and don't have to keep guessing. 

Increase performance:
Increase performance:
  • Increase plant availability 

  • Increase product/process quality 

  • Increase plant service life 

  • Efficient monitoring 

Cost reduction:
Cost reduction:
  • Reduce repair costs 

  • Reduce maintenance and service 

  • Reduce spare parts stocks 

Process optimization:
Process optimization:
  • Plannable and efficient maintenance 

  • Uncomplicated part replacement

  • Easily identify defective sensors

Create added value:
Create added value:

As an OEM for your customer. 

  • Reduce maintenance and service 

  • Improve quality of machines 

Disruptions in the production process due to unplanned downtimes can be prevented through the use of sensors. Monitoring sensors, such as temperature, pressure and level sensors, provide data on the condition of a plant. If this data is processed, it provides valuable information for the maintenance of the machines and thus enables successful preventive maintenance.

The benefits of condition monitoring

Condition monitoring systems allow changes, such as wear on individual components or decreased sensor performance, to be detected more quickly and machine maintenance to be optimized and proactive.

This optimizes the maintenance process and also increases safety for your employees. Furthermore, failures can be anticipated to avoid or minimize production delays and the costs that come with them.

Beyond these possibilities, the extensive information and data provided by condition monitoring systems offers the possibility of new business and pricing models for machines and plants.

Condition data helps you improve machines, processes and productivity
Downtime management
Seeing the need to take action before failures occur helps you manage downtime schedules
First step towards predictive maintenance
Condition monitoring is one requirement for being able to predict failures
Employee safety
More informed maintenance creates a safer workplace

What do you want to learn next?

You can download more information about this topic, however much experience you currently have with condition monitoring.

For beginners, a PDF fact sheet

  • It includes the top 5 facts about condition monitoring

  • Maintenance approaches

  • Tips to gather the right data

  • Answers about cost-benefit tradeoffs

  • An example return on investment calculation

For advanced, a digital whitepaper:

  • Example applications show where and how condition monitoring can bring real benefits

  • An easy guide to help you choose the right sensors and solution to match your requirements

Not sure about your level of knowledge? Take our six-question self-assessment and we will use your answers to send you the right content.

Balluff Condition Monitoring: A comprehensive portfolio that sets standards 

With a broad and systemically comprehensive range, Balluff offers suitable solutions for the efficient analysis of your machine data: From sensors that provide additional data for efficient condition monitoring through IO-Link, to standard systems with extensive analysis options and evaluation software, to customised overall solutions. From evaluation to concept to implementation - we are the right partner from the very beginning and will be happy to accompany you. 

Our customers solve complex problems in industrial production every day. We aim to make their work easier and more efficient. Our sensors provide valuable data about machines that increases reliability in the automation process and drives improvement. Our customers have benefitted from our solutions -- from simple to complex --for many years and we'd be happy to support you in implementing them as well.

Thomas Meissner, Strategic Incubation Manager at Balluff

Our technology for your success 

Condition detection, analysis, diagnosis: 

In addition to their core functions, like distance measurement or object detection, the components of the Balluff Smart Automation and Monitoring System (SAMS) provide you with condition data like vibration, temperature or operating hours. The best part: thanks to the IO-Link communication standard, the data you need is available uniformly everywhere, and as soon as you need it.    
Learn more about the functions of the components of the Smart Automation and Monitoring System.

A condition monitoring solution in an intelligent sensor 

In addition to the SAMS components, Balluff offers an intelligent condition monitoring sensor. The condition monitoring sensor measures various physical variables - such as vibration, temperature, humidity and ambient pressure - and supplies the recorded data to a higher-level system via IO-Link. The data obtained can be used not only for plant control, but can also be further evaluated and analyzed for diagnostic purposes. In addition, the sensor offers the possibility of defining limit values for pre-alarms and main alarms, so that certain states generate warning messages as soon as the defined values are exceeded. After evaluating the collected data, statements can be made about the condition of the machines and systems. Together with the warning messages, this data pool is a prerequisite for predictive maintenance. 

  • Multiple measured variables in one device: vibration, temperature, humidity, ambient pressure 

  • Integrated evaluation electronics with configurable data preprocessing 

  • Configurable events and status displays 

  • Quick to connect and easy to integrate via IO-Link 

  • Compact design 

Condition Monitoring Toolkit (CMTK) 

With the Condition Monitoring Toolkit (CMTK), we offer you a complete solution to monitor the condition of machines and processes. It contains everything you need: from sensors to data acquisition system to visualization software. And you benefit from great flexibility thanks to its compatibility with all IO-Link sensors, as well as simple operation thanks to the intuitive software. Thus, with the CMTK, you can implement condition monitoring entirely according to your needs in just a few minutes.

You need help?

Please contact us - We will be happy to support you!
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  • Industry brochure condition monitoring – continuously monitor the condition of machinery

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