Understand rare faults. Make machine conditions measurable.

Fault analysis

A machine black box for rare faults

Problem: A fault occurs only occasionally or under specific loads and operating states and cannot be reproduced during a service visit.

Approach: Depending on the plant, current, vibration, temperatures, analog process values and digital states are recorded together. ThermalDIAG Analytics then supports investigation of the sequence before, during and after the event.

Measurement task: One problematic machine and a defined measurement period are enough to begin.

Value: Decisions are based on the actual plant history instead of assumptions or isolated snapshots.

Existing equipment

Condition analysis and retrofit monitoring

Problem: An older or vendor-independent machine provides too little condition data, while replacing the machine or controller would be disproportionate.

Approach: Additional sensors and available machine signals can connect temperature, current, vibration, pressure, flow or other analog values with operating states.

Measurement task: A few relevant measurement points on one machine first show whether permanent monitoring provides useful value.

Value: Existing equipment gains additional condition information without necessarily replacing the existing controller.

Test tasks

Functional and endurance tests

Problem: During a test, actuation, feedback, cycle count and physical measurements need to remain traceably aligned in time.

Approach: ThermalDIAG can operate prepared digital outputs for non-safety-critical test sequences, check feedback, count cycles and record temperature, current or vibration at the same time.

Measurement task: One test item and a defined test cycle form a manageable first task.

Value: Small and medium-sized test tasks gain reproducible measurement and sequence documentation.

Boundary: ThermalDIAG does not replace a PLC, real-time or safety controller, or a prescribed inspection.

Biomass heating plants

Conveyors, pumps, fans and auxiliary equipment can be investigated together using current, vibration, temperature and available operating states.

Example: Observe one conveyor or pump group over a defined period.

ThermalDIAG does not intervene in safety-critical boiler or combustion controls.

Small hydropower plants

For older or individually configured plants, generator current, temperatures, vibration and available operating or auxiliary-system signals can be aligned in time.

Example: Observe one turbine-generator unit and investigate relationships between load, temperature and vibration.

Backup generators and test runs

Available electrical, mechanical and digital signals can be recorded during recurring test runs and compared across multiple tests.

Example: Document an existing test run and evaluate starting behaviour, load, temperature and vibration.

The additional documentation does not replace inspections required by law, standards or the manufacturer.