Preventing unexpected equipment failure by monitoring difficult to measure failure modes
OMRON Corporation (HQ: Shimogyo-ku, Kyoto; President & CEO: Yoshihito Yamada) will globally launch its K7DD-PQ Series of advanced motor condition monitoring devices, starting March 1, 2023 in Japan and then globally April 3, 2023. The series is the latest addition to OMRON’s family of condition monitoring devices that automate the monitoring of abnormalities on the manufacturing site in place of human workers. The K7DD-PQ numerically track trends in the deterioration and wear of servomotors, machine tools, and other equipment, in order to reduce inspection effort and prevent their unexpected failure.
With labor shortages intensifying in the manufacturing industry, there is growing demand for the automation and streamlining of maintenance work. On the manufacturing site, monitoring of the conditions of servomotors that frequently change speed and of motors on equipment with frequently changing loads (e.g., machine tool drills) previously relied on skilled veteran workers. Inspections and part replacements had to be conducted based on the experience and knowledge base of these workers. There is also a pressing need to implement solutions that prevent unexpected equipment downtime. To address these issues, OMRON began providing condition monitoring devices in December 2017. These devices implemented OMRON’s industry-leading sensing technologies and anomaly detection algorithms to monitor for equipment anomalies, thereby eliminating downtime losses on the manufacturing site. The company has since paved the path toward predictive maintenance solutions for monitoring 3-phase induction motor*1 conditions, thermal control panel monitoring, motor insulation resistance*2 monitoring and monitoring deterioration trends in resistance heaters.
The new K7DD-PQ can monitor the conditions of servomotors that frequently change speed, and of motors with rapidly changing loads. They can monitor a wide range of failures individually by monitoring over 400 types of features*3 from current and voltage measurements. Machine tool spindle motors for drilling, for example, can fail in many different ways: their blades may become worn, chips may get caught, their bearings may deteriorate, and so forth. As a result, these motors must be inspected for each of these possibilities. K7DD-PQ can be configured in advance, to monitor for each failure mode separately. They are also able to set thresholds automatically based on data collected by the support tool. These features allow for the automation and streamlining of maintenance tasks previously reliant on the experience and senses of skilled veteran workers, in order to prevent unexpected equipment failures.
By evolving its unique “innovative-Automation” concept, OMRON will continue to pursue new ways to achieve productivity suited for manufacturing of a future age, powered by “Autonomation beyond Human Ability” and “Advanced Collaboration between Human and Machines.” The company’s aim is to drive this productivity by innovative digital engineering, together with its customers, through the expansion of its lineup of condition monitoring device products.
Main features of the K7DD-PQ Series
K7DD-PQ advanced motor condition monitoring devices monitor the conditions of the entire motor equipment by obtaining current and voltage measurements through the motor’s power line.
- Applied technology 1: High-speed 2.5-μs sampling technology that catches even the most fleeting anomalies
- Applied technology 2: 6-channel simultaneous/continuous operation technology that processes data without omission or deviation
- Applied technology 3: 50-ms operating speed that keeps pace with variable-speed equipment
- Applied technology 4: Capacity to monitor over 400 types of feature values that enables exhaustive diagnosis of motor equipment
1. Enables monitoring of servomotors and induction motors that frequently change speed
Anomalies in a motor or its load often impact the motor’s rotation axis. Gaps between the rotor and stator and changes in torque stemming from deterioration manifest as changes in current and voltage, causing waveform distortion. K7DD-PQ monitor diverse feature to be able to distinguish between vibrations to the motor, impact to the motor, and changes in torque.
2. Delivers condition monitoring that can be self-contained within the manufacturing site
Using the cloud and data servers requires system building skills and coordination with IT administrators, and condition monitoring using conventional vibration sensors requires construction work for installing these sensors to the equipment to be monitored. K7DD-PQ can be retrofitted to the control panel to let you monitor motor equipment conditions and view anomalies locally, without having to learn new skills. By using host communications systems, you can also distinguish between different failure modes when alerts are issued by a K7DD-PQ.
3. Reduces inspection workload and delivers results reliably
K7DD-PQ are equipped with 50-ms operating speed and the capacity to calculate over 400 types of feature values, allowing them to identify many different failure modes of motors. Using this data requires advanced data analysis skills. The series offers a support tool that simplifies this analysis by selecting effective feature values and setting thresholds automatically to identify failure modes and root cause.
- 3-phase induction motors: Used in equipment such as pumps and fans, these motors are the most commonly used motors in factories and similar settings.
- Insulation problems: State in which insulation material for preventing electricity from leaking from the electrical circuit to the chassis has deteriorated, allowing electricity to leak. Insulation problems can lead to incidents that gravely impact equipment safety and productivity, such as electrocution, fire, and failure.
- Feature values: Values operated from current and voltage data obtained from the motor’s power line. These values are used to explore the correlation between this data and changes in motor conditions.
OMRON is advancing a unique “innovative-Automation” concept, creating new types of automation that drive the manufacturing revolution forward at the same time as realizing coexistence with the global environment and a sense of purpose for all workers, as well as contributing to the growth of sustainable industries.
As we look to the future of manufacturing, OMRON will pursue novel approaches to productivity in the form of “Autonomation beyond human abilities” and “Advanced collaboration between people and machines,” underpinned by “Digital engineering transformation” in order to enrich the future for people, industries and the globe by innovative-Automation.
About OMRON Corporation
OMRON Corporation is a leading automation company with its core competencies in Sensing & Control + Think technology, and is engaged in a wide range of businesses including industrial automation, healthcare, social systems, and electronic components. Established in 1933, OMRON has about 30,000 employees worldwide, working to provide products and services in around 120 countries and regions. For more information, please visit
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