Filter
Filter monitoring with IoT measures the differential pressure across a filter and shows how dirty it is. Operators change filters when it is actually necessary, avoid clogged filters and downtime, and save energy and material.
Filter at a glance
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Use cases
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Verified projects featuring Filter
Filter monitoring in coal plants: manual to LoRaWAN diff-pressure sensor
Increasing machine availability by monitoring hydraulic power units in test rigs
Determining the optimal maintenance time – predictive filter monitoring of a material distribution system
Condition-based filter monitoring in production
A modular solution for the future of wastewater treatment
Building technology digital: control system recognises potential in plant operation
Filter monitoring: change filters by condition, not by calendar
In the solution examples, pressure sensors measure upstream and downstream of the filter. The WIKA A2G-500 differential pressure sensor sends its values once an hour via LoRaWAN to a dashboard in the control room. At ifm, the AI-based LifetimeEstimator in the moneo platform calculates the remaining service life of each filter and reports the change with a defined lead time. WAGO forecasts contamination with analytics and automatically triggers the maintenance order in SAP. Where filter condition cannot be measured directly, Bosch Connected Industry evaluates temperature and pressure differences at the heat exchanger and the valve position.
The examples come from power generation, automation, automotive, building services and wastewater, mostly as filter monitoring within condition monitoring or predictive maintenance. In a coal-fired power plant, the WIKA solution replaces manual gauge readings on twelve different filter models. WAGO now cleans the filters of the material distribution system in its housing production only when needed instead of at fixed intervals. In a cathodic dip painting line, the Bosch Nexeed Industrial Application System detects clogged filters before an unplanned replacement of the paint bath becomes necessary.
Podcast episodes featuring Filter
Zoom into the WAGO Plant & Partner Ecosystem Enables Predictive Maintenance of a Material Distribution System
Siemens & AUDI AG – Digital building technology: Control system recognizes potentials in plant operation
Digital machine portals for packaging machinery – External procurement of spare parts and associated capital commitment – Retrofit for filtration systems
Filter monitoring: frequently asked questions
How does filter monitoring with IoT work?
Sensors measure the pressure upstream and downstream of the filter: the greater the difference, the more loaded the filter is. The values are sent by radio or over the network to a platform that records the trend. If the differential pressure exceeds a threshold, maintenance receives a warning via dashboard, email or ticket system. Manual inspection rounds and changes at fixed intervals are no longer needed.
Which differential pressure sensor suits remote filter monitoring?
Differential pressure sensors with their own radio connection are well suited to remote monitoring, because no cables need to be run through the plant. In a coal-fired power plant, the operator uses the WIKA A2G-500. It measures the pressure difference of individual filters in a range of 0 to 2,500 Pa and transmits the values hourly via LoRaWAN. WIKA also helped position the gateway for reliable coverage.
When is the right time to change an industrial filter?
An industrial filter should be changed when contamination starts to reduce the plant's performance, not when an interval expires. The ifm LifetimeEstimator calculates the remaining service life from the sensor data. WAGO only cleans filters when conveying capacity is about to drop below an acceptable level. At a car manufacturer, cloud data from Siemens also makes it possible to assess the quality of air filters and therefore of their suppliers.
How are hydraulic filters monitored?
Hydraulic filters are monitored via the differential pressure, which indicates the degree of contamination. In the ifm solution for hydraulic power units on test benches, the moneo platform records system pressure, fill level, tank and return temperature and pump vibration in addition to the filter. This allows filter cleaning to be scheduled at the optimal time, and cyclical checks are no longer required.
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