Byron Hernandez

Data collection is one of the most relevant topics of modern automation and industry. It is usually a costly and time-consuming task, especially in continuous processes. Our case study takes place in a sugar cane mill. The required continuous operation of a belt conveyor for bagasse transportation makes it a critical system in the overall production process. Therefore, a predictive maintenance tool is highly applicable here. We identified bearing housings as critical points for data collection intended for prognostics of the conveyor. However, given the number of points, the cost of a commercial solution becomes unfeasible by our company. This paper reports the development of low-cost devices for measurements and wireless transmission of vibration and temperature data from bearing housings. We assessed several sensor options and made decisions based on a cost-suitability commitment, which led to the design of the electronic devices. The devices were tested for correct operation, reliability (99%), and relative measurement errors under 1.2%. From the tests, we conclude that our proposal is appropriate for our case study’s industrial needs and budget restrictions.