Condition Monitoring

Proactively monitor equipment health and performance with our advanced Condition Monitoring solutions. By delivering real-time insights, our system helps prevent equipment failures, optimize maintenance schedules, and extend asset lifespan.

 

Condition Monitoring IOT 101

Applications

Use Cases

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What is Condition Monitoring?

Condition monitoring is a critical process in asset performance management that involves the continuous or periodic assessment of machinery and equipment to detect signs of wear, degradation, or potential issues before they lead to equipment failure. By using advanced condition monitoring techniques – such as vibration monitoring, thermal imaging, and oil analysis – organizations can gather real-time data on the health of their assets.

This proactive approach enables maintenance teams to make informed decisions, reduce unplanned downtime, and extend the lifespan of critical equipment. Ultimately, condition monitoring plays a key role in optimizing operational efficiency and ensuring reliability across logistics and industrial operations.

How does Condition Monitoring Work?

Condition monitoring works by collecting and analyzing data from various sensors installed on critical machinery to assess their real-time operating condition. In a typical condition monitoring system, operating process sensors are strategically placed on rotating equipment—such as motors, pumps, and compressors—to detect changes in performance and identify early signs of mechanical issues.

One of the most widely used methods is vibration analysis, which measures oscillations and patterns to uncover imbalances, misalignments, or bearing failures. The data gathered is then processed through advanced data analysis tools to identify trends and anomalies, allowing maintenance teams to take corrective actions before costly breakdowns occur. This systematic approach helps ensure equipment runs smoothly, safely, and efficiently.

As an award-winning GPS manufacturer, Digital Matter takes pride in seamlessly integrating condition monitoring, ensuring our clients experience the power of real-time condition tracking.

Benefits of Condition Monitoring

Condition monitoring offers a number of benefits for industrial operations, especially when managing complex systems and large fleets of equipment. By implementing condition monitoring, companies can detect issues early, reduce downtime, and increase the reliability of critical assets. This is particularly valuable when servicing multiple machines across a facility, as it allows maintenance teams to prioritize work based on real-time data rather than guesswork.

It’s especially beneficial for rotating machinery, such as pumps, turbines, and motors. These components are prone to wear and misalignment, which can lead to sudden failures if not addressed quickly. With continuous monitoring in place, teams can track vibration, temperature, and other key parameters to ensure each machine is operating within safe limits.

Other key benefits include:

  • Reduced Downtime: Early fault detection prevents unplanned shutdowns, saving businesses from productivity losses and costly repairs.
  • Optimized Maintenance Scheduling: CM allows for predictive maintenance planning based on real-time data rather than reactive approaches. This reduces labor costs and improves resource allocation.
  • Extended Equipment Lifespan: By addressing issues before they escalate, CM prolongs the operational life of machinery and minimizes wear-and-tear.
  • Enhanced Safety: Proactive monitoring reduces the likelihood of accidents caused by equipment failures, contributing to safer working environments.
  • Cost Savings: CM minimizes repair costs, energy consumption, and waste while maximizing operational efficiency.

Applications of Condition Monitoring across Industries

Condition monitoring is widely used across a range of industries to enhance operational reliability and reduce unplanned downtime.

Tools & Manufacturing

It ensures optimal performance of motors, compressors, pumps, and other rotating equipment by detecting early signs of wear or failure, allowing for timely maintenance.

Energy

Condition monitoring plays a crucial role in tracking the health of turbines and generators, helping prevent unexpected outages and ensuring consistent power supply.

Transportation

In fleet management, it monitors engine health and performance, enabling predictive maintenance and extending vehicle lifespan.

Cold Chain Monitoring

Monitor temperature, humidity, and environmental conditions in real time to protect temperature-sensitive goods during storage and transit.

Equipment Tracking

Monitor run hours, impact, tilt, and unauthorized use to improve utilization, enable predictive maintenance, and reduce downtime.

Tool Tracking

Monitor tool usage, run hours, impact events, and movement with compact GPS and Bluetooth® tracking devices. Improve preventative maintenance and reduce losses with real-time visibility.

Supply Chain Visibility

Gain real-time insights into the condition and location of critical assets across complex global supply chains.

Agriculture

Monitor soil moisture, temperature, tank levels, and equipment usage with rugged IoT sensors to optimize crop yields, livestock health, and resource efficiency.

Condition Monitoring Use Cases

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Critical Aircraft Part Tracking and Condition Monitoring with IoT

As a result of COVID-19 lockdowns in 2020, one of the world’s largest manufacturers of high-value aircraft parts was forced to leave critical assets unattended for several weeks in an uncontrolled environment. Due to high humidity levels, the critical aircraft parts corroded and were unusable, resulting in a substantial (hundreds of millions of dollars) financial loss for the company and its aviation partners.

To improve visibility in their supply chain, the manufacturer selected Digital Matter’s Oyster Edge battery-powered Indoor/Outdoor GPS asset tracking and Bluetooth Gateway to track and monitor the location and condition of thousands of their critical aircraft assets as they move globally through production, storage, and delivery.

By providing essential visibility of critical high-value assets in transit, the Oyster Edge has allowed the manufacturer to authenticate the location of goods at any time, track speed of movement and arrival times, monitor storage conditions, and streamline the problematic movement of goods. Implementing the Oyster Edge has also created a competitive advantage with sustainability as there is less ‘waste,’ or lost goods due to improper storage.

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Livestock Monitoring in the Alpes

Located in the harsh mountains of France, Alpes-éco is innovating the world of farming. Disrupting the Ag-tech industry, they have created a new way to monitor and manage livestock, Livestock Guardian Dogs, and natural disaster prevention efforts in the mountainous regions of France and Switzerland using IoT technology.

To combat the extreme conditions of the mountains, Alpes-éco needed reliable GPS tracking devices that could provide accurate data to help monitor the condition of their livestock.

Utilizing the Oyster3, Oyster3 Bluetooth®, and Remora3, they have deployed over 100 devices across the mountainous regions of France and Switzerland. Alpes-éco uses the data collected from these devices to:

  • Optimize fodder areas
  • Monitor and manage the health of livestock and Livestock Guardian Dogs
  • Protect livestock from large predators

The incorporation of Bluetooth® Low Energy (BLE) technology via the Oyster3 Bluetooth® and Remora3 has notably elevated Alpes-éco’s capabilities in managing livestock. This innovative use of BLE enables precise location tracking, early detection of abnormalities among animals, and optimization of grazing ranges.

Articles on Condition Monitoring

Stay up to date with the latest trends, insights, and innovations related to Condition Monitoring.

 
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Featured IoT Asset Tracking Devices

Supplement your RTLS solution with our range of highly configurable wired and battery-powered IoT asset tracking devices.

23 Products

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Barra Core

Barra Core

NB-IoT

Compact and rugged battery-powered asset tracker with magnetic activation and tamper detection for ultra-low-cost indoor/outdoor visibility.

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Barra Edge

Barra Edge

LTE-M (Cat-M1) NB-IoT

Compact and rugged battery-powered GPS tracker with magnetic activation and tamper detection for cost-effective indoor/outdoor asset tracking.

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Barra GPS

Barra GPS

LTE-M (Cat-M1) NB-IoT

Compact and rugged battery-powered GPS tracker with magnetic activation and tamper detection for cost-effective outdoor asset tracking.

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Barra Radar BLE

Barra Radar BLE

Bluetooth®

Battery-powered Bluetooth® radar sensor with millimeter-level precision for level and object detection.

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Oyster3 GPS

Oyster3 GPS

LTE-M (Cat-M1) NB-IoT

Rugged battery-powered GPS tracker for high-precision outdoor asset tracking.

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Oyster3 LoRaWAN®

Oyster3 LoRaWAN®

LoRaWAN®

Rugged battery-powered GPS tracker for high-precision outdoor asset tracking on LoRaWAN networks.

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Oyster Edge

Oyster Edge

LTE-M (Cat-M1) NB-IoT Bluetooth®

Rugged battery-powered GPS tracker and Bluetooth® Gateway for asset tracking and wireless condition monitoring.

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Oyster3 BLE

Oyster3 BLE

LTE-M (Cat-M1) NB-IoT Bluetooth®

Rugged battery-powered GPS tracker and Bluetooth® Gateway for asset tracking and wireless condition monitoring.

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Oyster3 Global

Oyster3 Global

2G 4G LTE Cat 1bis

Rugged battery-powered GPS tracker with 4G/2G connectivity for global asset visibility.

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Oyster Sigfox (End of Life)

Oyster Sigfox (End of Life)

Sigfox

Rugged battery-powered GPS tracker for high-precision outdoor asset tracking on Sigfox networks.

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Manta Fusion

Manta Fusion

LTE-M (Cat-M1) NB-IoT Bluetooth®

Rugged battery-powered GPS tracker and Bluetooth® Gateway with magnetic activation and tamper detection for asset tracking and wireless condition monitoring.

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Remora3

Remora3

LTE-M (Cat-M1) NB-IoT Bluetooth®

Rugged GPS tracker and Bluetooth® Gateway with the longest battery life on the market for asset tracking and wireless condition monitoring.

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Remora3 Global

Remora3 Global

2G 4G LTE Cat 1bis Bluetooth®

Rugged GPS tracker and Bluetooth® Gateway with 4G/2G connectivity for global asset tracking and wireless condition monitoring.

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Yabby3

Yabby3

LTE-M (Cat-M1) NB-IoT

Compact and rugged battery-powered GPS tracker for reliable outdoor asset tracking.

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Yabby3 LoRaWAN®

Yabby3 LoRaWAN®

LoRaWAN®

Compact and rugged battery-powered GPS tracker for outdoor asset tracking on LoRaWAN networks.

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Yabby Edge Cellular

Yabby Edge Cellular

LTE-M (Cat-M1) NB-IoT

Compact and rugged battery-powered GPS tracker for indoor/outdoor asset tracking.

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Yabby Edge LoRaWAN®

Yabby Edge LoRaWAN®

LoRaWAN®

Compact and rugged battery-powered GPS tracker for indoor/outdoor asset tracking on LoRaWAN networks.

OBDII

Bolt2

Bolt2

LTE-M (Cat-M1) NB-IoT

OBDII-powered GPS tracker with back-up battery for plug-and-play fleet and vehicle tracking.

OBDII Wired

Dart3 BLE

Dart3 BLE

LTE-M (Cat-M1) NB-IoT Bluetooth®

Wired GPS tracker and Bluetooth® Gateway with flexible I/O options for vehicle and fleet management and wireless sensor monitoring.

Wired

G70 BLE

G70 BLE

LTE-M (Cat-M1) NB-IoT Bluetooth®

Rugged wired GPS tracker and Bluetooth® Gateway with flexible I/O options for fleet, vehicle, and equipment management in harsh environments and wireless sensor monitoring.

Wired

G150

G150

2G 4G LTE Cat 1bis Iridium Satellite Bluetooth®

Rugged wired GPS tracker with Bluetooth® Gateway, extensive I/Os, global 4G/2G connectivity, and optional Iridium Satellite for critical or out-of-coverage deployments.

Wired

G62 LoRaWAN®

G62 LoRaWAN®

LoRaWAN®

Rugged wired GPS tracker with flexible I/O options for fleet, vehicle, and equipment management on LoRaWAN networks.

Condition Monitoring FAQs

What is condition monitoring and why is it important?

Condition monitoring is the process of tracking the performance and health of equipment using sensors and data analysis. It helps detect early signs of wear or failure, allowing for timely maintenance and reducing the risk of costly downtime.

What types of equipment benefit most from condition monitoring?

Rotating machinery like motors, pumps, compressors, turbines, and engines benefit greatly from condition monitoring. These assets are prone to mechanical issues that can be identified early through techniques like vibration analysis and thermal monitoring.

How does condition monitoring differ from traditional maintenance?

Traditional maintenance is often time-based or reactive – performed after a failure occurs. Condition monitoring supports predictive maintenance by using real-time data to identify potential issues before they lead to equipment failure, improving efficiency and reducing costs.

 

What techniques are used in condition monitoring?

Common condition monitoring techniques include vibration analysis, thermal imaging, oil analysis, and ultrasonic testing. These methods help detect specific problems such as misalignment, overheating, contamination, or wear in machinery components.

Is condition monitoring expensive to implement?

While there is an initial investment in sensors, software, and setup, condition monitoring often pays for itself by reducing unplanned downtime, minimizing repair costs, and extending equipment life. It’s a cost-effective solution for maintaining high-value assets and optimizing operations.


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