Productivity, Reliability, Energy Usage
Learn how to get this information and more out of your current transformer.
What Can Be Learned by Monitoring a Single Sensor?
It is common for devices such as current transformers, discrete sensors, vibration sensors, and tower lights to be installed on equipment to accomplish one job—for example, to sense a package before it gets diverted or trigger an alarm if a value goes out of range. However, these devices can tell you much more if you collect and track data from I/O signals over time.
Current Monitoring
Using a current transformer to monitor the current draw of a machine or motor provides a series of measurements over time, leading to valuable insights. For example, if you can see precisely when a motor uses excess power (in Amps) to perform regular tasks, you can determine which conditions are causing this strain. If you isolate the specific causes (be they conveyor jams, weight overages from material quantities, or some similar event) and then adjust machine settings accordingly, you can prevent both mechanical failure and also costly unexpected downtime, if major repairs would be necessary.
Monitor Current Draw over Time
Even if you only measure the amount of current a machine uses, and compare that to a baseline value, you can capture metrics that tell you a great deal about the performance of your automated systems.
Current monitoring paints a picture of machine utilization and ability over time. Are you using your machinery efficiently? Are your current motors adequate for your production needs, or do should they be replaced with more powerful components?
Current transformer monitoring amperage on an electric motor
S15C Series: In-Line Converter w/ Current Transformer
Reduce Energy Costs and Improve Maintenance
Conversely, are there opportunities to reduce energy consumption (and by extension, electricity costs) when machines do not need to run at full power? You might discover opportunities to improve the scheduling of machine operations, and possibly increase production quantities while lowering per-unit energy usage.
If there are deviations from the baseline level of current draw, this could be indicative of a part that is starting to fail, such as a slipping conveyor belt, a motor starting to burn out, a bent shaft or rotor bar, et cetera. Taking quick action to replace or repair worn-out parts early on could prevent a catastrophic shutdown.
Take Advantage of Real-Time Data
To maximize profitability, manufacturers should embrace and leverage data analytics. And a simple, easy-to-install current-monitoring solution provides actionable data to make production more efficient, cost-effective, and competitive.
Current monitoring outputs actionable data. When you combine this information with readings from vibration or temperature sensors—or “tap in” to your existing industrial sensors using Snap Signal products—you gather a holistic view of the health of your entire factory infrastructure in real time.
Current transformers installed on injection molding machine
Unlimited Industrial Applications
Current transformers can tell you so much more than the Amp draw of a device at a specific moment. When analyzed over time, they can provide additional insights into the health and performance of equipment. For example, they can be used to confirm that a remote asset is running. If users want to verify that an exhaust fan is on, a current transformer can transmit signals that indicate a current load increase on the motor. This same technique can be applied to compressors, pumps, and other powered equipment.
Similarly, current transformers can help verify that powered equipment is shut off when not in use, to prevent costly unnecessary energy consumption. They even provide a cost-effective solution to ensure that lights are not left on in an unoccupied room or area of a production facility. In addition, by monitoring current draw in this way, users can quickly detect maintenance issues such air leaks in systems.
For injection-molding applications, current transformers can be installed to ensure that plastic pellets are being melted correctly. A typical system uses a barrel surrounded by ten heater bands that each draw current. If any one of those heating stages fails to run, it could cause quality or scrap-related issues. Using current transformers to monitor the heating bands helps to verify proper operation and/or immediately alert maintenance teams about power-draw issues that need to be addressed.
Current monitoring can be used for equipment that runs continuously or in cycle counts, and it can lead to productivity improvements. For example, in facility applications, current transformers make it possible for users to calculate run time or run hours of machines or motors for long-term tracking and cycle counts. Adjustments can then be made to cycles per hour in production processes, so that operations run at the most efficient speeds.
