System basic structure

At the base of SED lies a module endowed with a microprocessor that administers the GSM modem’s resources. This module is named "gsm_manager" and has its own functioning algorithm (source code) and communication protocol with the GSM modem and the PLC module (automate programmable on base of the microprocessor).

Between the gsm_manager module and the application module (PLC) there is a parallel communication system called data base line. On this data base line, the order and importance of the events are established. If necessary, the audio/video modules may be connected to the "gsm_manager" module.

Power unit

The SED deivce may be supplied from various usual power supply units (220Va.c./380Va.c./24Vc.c./12Vc.c/5Vc.c), the main power unit being the storage cell, that allows a permanently functioning (in the capacity limits) of the system. The SED device transmits notes regarding the storage cell’s status in various situations, in capacity percentage. Virtually, the storage cell may have a voltage of more then 3.7 V a.c. and an amperage of minimum 1.5 A.

The external power supplies may by of any type and value, the minimum and necessary condition is the possibility to ensure the charging capacity of the battery, in the limits of its parameters given in the battery manufacturer’s catalogue.

The software and the application interface

The application algorithm (software/binary code) that specifies the handling of the monitored information may be found in the program memory of the application module (PLC). These signals are transformed in binary codes that will be send in the future on the parallel data base line to the "gsm_manager" module. SED is compatible through standard communication using the RS232/USB/TCP/IP protocols with the Windows (XP, 7-8-10) operating systems, both for data emission and reception.

It was also recently developed an interface for Android operating system installed on smartphone and / or tablet. The communication program allows a direct connection with the radio modules for adjusting the reception/emission parameters, needed as a quality characteristic for data interchange. At the monitored results reception, an electronic block, called “gsm_dispatcher”, may be found. This module communicates with the PC through one of its ports.

The information received by the computer (PC) may be stored in a data base (server). These may be subsequently listed in order to obtain a physical evidence of the events, for example, to prepare a service report.

The system advantages

The System for Distance Supervision of Industrial Equipment (SED) presents the following advantages:

- an exact perception upon the nature of the defaults appeared at the equipment
- high reliability in operation for the industrial equipments
- safety in application because of the equipment’s monitoring
- a reduced intervention time for service team
- reduced service costs for industrial equipments equipped with SED device.

Elevators monitoring

Preventive and predictive maintenance of ELMAS elevators, along with monitoring safety alerts, ensuring operational efficiency, and tracking elevator movement, are crucial in order to maintain the equipment in optimal working condition.

This approach ensures high-performance results with sustainable equipment, characterized by high productivity and low maintenance costs. It also significantly enhances the safety of elevator operations. Both preventive and predictive maintenance must be continuously managed and maintained by elevator manufacturers or users.

The SED remote monitoring system offers round-the-clock supervision and advanced data analysis of operations, wear, fault detection, and alerts in the form of error/warning codes. SED is a comprehensive solution that includes analyzing data stored in the cloud, accessible via a mobile app. Data is transmitted by sensors and hardware specifically integrated and adapted for ELMAS elevators.

Benefits for Elevator Manufacturers

SED can be tailored to fit your specific needs and elevator setup. It plays a crucial role in elevator predictive maintenance and lifecycle management, improving the quality of support provided to end users. It also helps enhance product quality and reduce warranty costs by remotely assessing anomaly/defect report data.

Elevator maintenance can be scheduled and optimized to minimize unplanned downtime, enhance equipment safety and productivity, extend lifespan, and reduce spare parts usage. The SED system provides information and notifications on critical parameters such as operation details, safe working period (SWP), motor duty cycle, vibration, overloads, emergency stops, temperature, and the remaining lifespan of selected components (motor, brake, hoisting cables, etc.) via email alerts.

Benefits for Elevator Users

The monitoring system is fully integrated, generating customizable reports and alerts tailored to your needs, elevator setup, and model.

Daily or weekly reports provide data on elevator usage, operating information, overloads, and safety alerts, which can be used to remotely assess the condition and safety of the elevator.

Remote Monitoring and Preventive Maintenance Parameters for Elevators

Motor Voltage and Current Monitoring

This information helps track motor wear. An advanced algorithm-based analysis is used to detect anomalies and deterioration while operating the motor. The monitoring system sends an advance notification to the user for preventive maintenance in order to avoid costly breakdowns.

Engine Temperature Monitoring

This information is crucial in order to prevent costly motor burnouts. The system sends timely alerts if the temperature exceeds safe limits, helping to avoid major breakdowns.

Hoisting Motor Vibration Monitoring

This long-term solution monitors motor wear over long periods of time (months or years). The algorithm notifies the user when general motor preventive maintenance is required. An increased vibration level can signal impending failure.

Elevator Use Monitoring

Equipment operational data is collected from button presses, movements, stops, travel direction, and hoisted loads. This information is consolidated to measure the operational efficiency and remaining lifespan of the elevators.

Motor CDF (Cyclic Durability Factor)

“Motor CDF” is calculated using operational parameters over duty cycles, including the frequency and duration of typical operations. It is also used to alert the user if CDF usage exceeds the set limits.

Motor Overload and Load Monitoring

Motor overload and actual load are monitored using a combination of current and load sensors. This information helps track elevator usage under specified load conditions.

Motor Brake Failure Monitoring

The brake air gap is monitored using sensors. Brake fault alerts are sent if the air gap exceeds the safety limits. This helps minimize the risk of the cab falling by detecting brake faults early.

SCADA, VFD, PLC Monitoring

The monitoring system is interfaced with the automation systems using customized protocols in order to facilitate the monitoring of control, fault, and operation status parameters, etc. This also helps provide a more in-depth analysis of the elevator operating conditions, faults, etc.

Safe Design Working Period (SWP) Monitoring

Advanced algorithms are used to calculate the elevator's long-term safe working period by analyzing operational history, CDF, and load conditions. This provides valuable information about the elevator’s working period and lifespan.

Cable Faults

The system monitors faults such as loose cables and issues instant alerts to prevent accidents.

Elevator Monitoring and Data Analysis, Reports, and Alerts

The SED Cloud data analytics system has two main functions:
- the dashboard and reports providing daily operational information
- emergency operations, emergency intervention alerts/alarms.

Standard daily and weekly reports are sent to the CALL CENTRE via email. Reports can also be requested through a web interface. Alerts are typically sent via email, SMS, or similar means to prompt rapid corrective actions.

Monitoring System for Elevator Preventive Maintenance

General Features

This system includes sensors and transducers, a cloud app, and an optional smartphone app (Android). Sensors are placed on various parts of the elevator, such as the electric motor, the three-phase power line, the elevator junction box, the hoisting cable, or the skids. They collect information and send it to a hardware device.

The hardware monitoring device is usually located in the elevator's general junction box. All sensor wires are connected to this device. Data collected by this device is periodically sent to the cloud server via GPRS communication.

The cloud server gathers data from several such hardware devices, displays it in the browser, analyses it for long-term pattern detection, and stores it for future use. Data can be accessed on-demand from a PC (using a browser) or a smartphone (Android app). This process enables remote monitoring from any location provided you have the necessary access credentials.

Extended Features

The system is equipped with remote firmware upgrade capabilities. Thus, the need for on-site visits to update the firmware with new features or bug fixes is eliminated. The system also includes a built-in battery that sends tampering alerts such as power failure, opening the box, etc. These alerts are sent to the server before losing power. This process discourages the malicious tempering of the monitoring system.

The monitoring system also enables the connection of external devices such as VFDs, PLCs, or data loggers. The communication protocols of such devices must be known so that they can be properly integrated into the system to ensure they work seamlessly with the existing electronic equipment.

In the event of a GSM signal loss, the system stores the data locally. Once the connection is re-established, the stored data is uploaded to the server. Therefore, even if connectivity is lost, no data will be lost.

As the hardware and software are designed and developed by ELMAS SRL, modifications, additional features, and customizations of software screens, sensors, and monitoring system functions are possible. This provides users with the unique advantage of having a personalized system.

Overhead travelling cranes monitoring

Motor voltage and current monitoring

This information is used to monitor the health of the engines. Using advanced analysis based on specific algorithms, anomalies and deteriorations in engine operation are detected. This notifies the user in advance to carry out preventive maintenance and thus avoid costly breakdowns.

Motor temperature monitoring

This information is important to prevent the motors from overheating, which could lead to their failure and expensive replacement. The system sends timely warnings when the temperature exceeds a safety limit to prevent damage.

Hoist motor vibration

This is a long-term monitoring solution that tracks engine wear over a long period of time - months or years. The algorithm informs the user when it is time for general preventive maintenance of the engine mechanics. For example, higher vibration could be a symptom that precedes an impending failure.

Usage monitoring

Monitoring the use of the crane or elevator travel. The operating data is recorded via the contacts of the travel buttons and the travel limiters. This is necessary to keep track of the duration and the different types of movements. This information is then consolidated to measure operational efficiency and remaining lifespan.

CDF (Cyclic Duration Factor) for motor

“Motor CDF” is calculated based on operating parameters related to work cycles, which include the frequency and duration of typical operations. This includes starting, running time with or without load, electrical braking and idle time. It is used to alert the user when CDF usage exceeds set limits.

Motor overload and load monitoring

Motor overload and actual load are monitored using a combination of current and load sensors. This information is used to track equipment usage under specific loading conditions.

Motor brake failure monitoring

The air gap of the brake is monitored by sensors. Brake fault alerts are sent when the air gap exceeds safe limits. This helps to minimize by detecting brake faults.

SCADA, VFD and PLC monitoring

The monitoring system interfaces with automation systems with customized protocols for monitoring control parameters, errors, status, etc. This allows detailed analysis of the operating conditions of the elevators and cranes, errors, faults etc.

Safe Design Working Period (SWP) monitoring

The long-term safe operating life of the elevators and cranes is calculated using advanced algorithms and operating history, CDF and loading conditions. This provides information about the calculated duration of use and the actual service life of the equipment.

Crane cable faults

Loose cable faults are monitored and alerts are issued immediately to prevent cable failures and other safety risks.

Features of the overhead travelling crane monitoring preventive maintenance system

The system is fitted with remote firmware upgrade. There is no need to visit the website to update the firmware with new features or bug fixes. Instead, it can be done right from your office. It has a small built-in battery, which indicates tampering with the device, such as power off, box opening, etc. This warning is sent to the server (within minutes) before the electronic parts run out of power. This will discourage malicious manipulation of the device. External devices such as VFDs, PLCs, data loggers can be connected to the system. The communication protocol of these devices must be known so that it can be implemented into the system to work with the existing electronic devices. In the event of a GSM signal failure, the system saves the data locally. This data is then uploaded to the server once connection to the server is restored. So, even in case of connectivity loss, there is no data loss. Since the hardware and software are designed and developed by ELMAS SRL, we can make changes, add functions and customize software screens, sensors and functions. This offers the user the unique advantage of receiving a customized system.

Industrial equipment’s monitoring

The system for distance survey of the equipment (SED) may also be fit on industrial installations, such as: industrial cranes, escalators, forklfit trucks, automatic storage systems, automatic auto-parking systems, etc. The minimum and necessary condition is for the device to be situated in the covered area of the signal delivered by the GSM operator. This is a very important condition especially in case of mobile applications, that is those that are moving with the SED device inside or outside the covering area of the signal.

In this case, SED is able to memorize the events that took place and couldn’t be transmitted to the place where monitoring is interpreted by scanning the electromagnetic field and finding the timely moment for the transmission. In this case, the information time may increase appreciably. For each industrial application type, the PLC module must be reprogrammed, depending on the requirements for the monitored data. This requires realizing the application software for the PLC micro-controller.