Transformer

A surface probe measures the temperature directly on the transformer, where hotspots develop. In the ifm solution, this is the TS2229, whose analogue signal is converted into an IO-Link signal by the TP3231 evaluation unit. Via an IO-Link master, the values reach the moneo platform every second. If a limit value is exceeded, moneo automatically sends an email to the employee responsible.

IoT makes transformer maintenance condition-based because maintenance teams can see the operating state live. According to ifm, without monitoring, malfunctions are often detected late or only when a machine stops. In the ifm solution, the temperature probe on the transformer is coupled to an operating hours counter that counts at a faster rate at high temperatures and at a slower rate at low ones. The count therefore reflects thermal load, not just running time.

It matters because an overheating transformer is a hotspot that can damage components in the control cabinet and lead to operational failures. According to ifm, without continuous monitoring, malfunctions are often only detected when a machine stops. ifm therefore uses the LDH292 multisensor to measure temperature and humidity inside and outside the cabinet, so that ambient influences are taken into account, and also measures directly on the transformer. Limit values are defined using the data sheets of the installed devices.

At plant level, transformer data becomes visible when an analytics platform combines existing meter data from SCADA and PLC systems. A rolling bearing manufacturer in Bangalore uses Itanta Analytics to bring together more than 80 energy meters, including compressors, chillers, furnaces, air handling units and transformers. The “Main Consumption Overview” dashboard shows consumption from grid power, a diesel generator and solar, along with key figures for the power factor and transformers. The platform was set up without any coding.