OMRON launches K7TM condition monitoring device for predictive maintenance of heaters

OMRON has launched the new K7TM condition monitor for heater equipment used especially in automotive and FMCG industries. The K7TM visualizes deterioration tendencies to enable predictive maintenance and contributes to the realization of a carbon-free society.

At manufacturing sites, sudden equipment failure leads to unplanned downtime and has a major impact on the productivity of the entire plant. Condition monitoring devices from OMRON combine powerful sensing technology with algorithms to detect abnormal conditions. These devices can be easily attached to existing equipment.

The new K7TM from OMRON enables automatic measurement of the appropriate resistance value*¹ of the heater while in operation and visualizes the deterioration tendency of the heater. By accumulating rate-of-change data of resistance values for each heater, maintenance activities can be timed in advance according to the heater status. This minimizes production downtime associated with regular heater maintenance. Reducing the thermal energy needed during a restart also helps minimize the energy loss from the heaters.

As the new K7TM can constantly measure the electric power consumed by each heater, combined with temperature data, it helps detect event the slightest signs of abnormal conditions in the facility. This contributes to maintaining the optimum conditions for ensuring product quality. Sudden heater failures can be eliminated, while reducing energy consumption in production, contributing to CO2 reduction.

To reduce unexpected downtown and wasteful costs due to heater burnout

Heater equipment that operates at high temperatures is more likely to experience unplanned downtime due to heater burnout. Preventing burnout requires the heater’s condition to be monitored, which was previously a time consuming and costly task, which can now be automated with the K7TM.

Issues concerning heater burnout

Downtime resulting from heater replacement and warm up is time consuming

As the heater burns out, production fallout will impact overall efficiency and profitability

Planned maintenance costs associated with heaters are currently a manual and labor intensive process

Main features and of the K7TM series:

• Easy to retrofit onto existing equipment
• Automatic measurement of the resistance of the heater during equipment operation to determine the deterioration tendency of the heater
• Reduce dependency on experienced maintenance staff
• Possibility to collect measurement data remotely using network connections
• Contributing to quality maintenance and energy reduction

^{*¹ Resistance value: If the heater is used for a long time, oxidation will advance and the heater wire will become thinner, resulting in disconnection of the heater. As a result, the resistance of the heater increases. Disconnection of the heater has a great impact on the productivity of the equipment.}

Appropriate heater conditioning monitoring, independent from temperature control method, heater temperature characteristics, and location

The K7TM Heater Condition Monitoring device can measure the resistance values of resistive heaters properly and periodically allowing for heater condition and trend monitoring both on site and remotely

Eliminating heater burnout reduces unplanned downtime, profit loss from yield issues and replacement part costs

Heater resistance value trends are not able to be determined using the basic voltage/current calculation since the temperature controller and heater characteristics influence this calculation. The K7TM is able to measure the resistance values regardless of these influences by filtering them out of this calculation. Additionally, the K7TM is able to monitor the deterioration trends in heater resistance by comparison with historical resistance values when used in the same environment.

Heater temperature characteristics

Depending on the type of heater, the resistance value may vary greatly depending on the temperature. Heater temperature characteristics need to be considered in order to monitor proper heater deterioration trends. Therefore, it is necessary to constantly monitor the heater resistance value at the same timing as the heater temperature.

Collecting measurement data remotely using network connections

The K7TM allows you to monitor condition both on site and remote without requiring on site visits.

Easy to retrofit onto existing equipment

Condition monitoring can be achieved by using a CT clamp on the power line of the heater and connecting voltage lines to each side of the heater.

Predictive maintenance that quantifies the deterioration state of the heater

By converting condition of the heater into a numerical value called the rate of change of the heater resistance value, scheduled maintenance based on the numerical value becomes possible. It also enables maintenance of heater equipment that does not depend on skilled personnel.

Ready to perform maintenance based on the degree of deterioration from heater resistance values

The K7TM can monitor the state of the heater by the rate of change of the heater resistance value and monitor the state and tendency of each heater, so it is possible to determine when replacement is necessary, so it is unplanned while utilizing the remaining life of the heater. You can reduce the possibility of downtime. In addition, maintenance that does not depend on skilled people becomes possible.

Using reference Resistance Value Change Rate to determine replacement

Previously there were challenges in determining correct service and replacement time on heater equipment. Since the K7TM can capture deterioration trends in heater resistance values change rate and trigger alarms when a threshold is reached, the user is able to determine the optimal time to service or replace heater equipment.

Note 1. The K7TM captures the heater deterioration due to oxidization by monitoring changes in the heater resistance value. The Unit cannot capture the deterioration due to other factors.

Note 2. Set an appropriate threshold that suits your environment as the trends toward deterioration of heater may vary depending on the heater type and the use environment.