Condition-based maintenance is a modern approach to preventive maintenance that leverages equipment monitoring to determine optimal timing of maintenance. It’s closely related to predictive maintenance.
Instead of utilizing fixed maintenance schedules, CBM relies on real-time data from sensors (that measure, e.g., a device’s temperature, pressure, flow…) and anomaly detection. When the data start signaling that potential problems may occur soon, the company’s system generates a task for the maintenance team that fixes the machine just in time.
Condition-based monitoring often relies on data from:
- Vibration sensors—Identify abnormal oscillations that may be signs of loose parts or other problems.
- Infrared cameras and temperature sensors—Detect overheating.
- Acoustic and ultrasonic sensors—Acoustic sensors detect abnormal operation sounds that may indicate mechanical issues. Ultrasonic analysis focuses on discovering leaks, defects, and cracks in a piece of equipment.
- Electrical analysis—Searches for changes in measurements like voltage, current, resistance, etc. that may indicate overloads, circuit faults, and other issues.
- Oil analysis—Finds changes in oil properties that may signal contamination or wear particles.
- Pressure analysis—Monitors shifts in pressure levels in machines that carry gas, water, or other fluids.