WITTENSTEIN’s IIOT: cynapse® & Health Index with utilisation radar
Within the range of Smart Services offered by the cynapse® functionality, Health Index provides a clear picture of the actual “health status” of gearboxes – whether they are operating correctly or showing early signs of wear that could lead to unexpected failure. This diagnostic tool continuously monitors and analyses drive train operating data in real time, promptly detecting critical conditions and anomalies. It is a valuable ally in preventing unplanned downtime and optimising predictive maintenance strategies.
Ergonomic data visualization
Gearbox data – collected via integrated cynapse® sensors – together with operating parameters such as torque and speed, are displayed through an intuitive interface featuring a digital traffic-light indicator based on three colours: green, “No anomalies”; yellow, “Changes detected, maintenance recommended”; red, “Risk of imminent failure, replacement required”. In addition, the utilisation radar shows whether the gearbox is operating consistently within permitted load limits. In practical terms, it allows users to assess whether the gearbox is being used correctly, whether it is subject to excessive stress, and which monitored parameters are exceeding attention thresholds. This is crucial information, helping to optimise service life by preventing overloads that could shorten component lifespan or lead to premature failure.
Real-time monitoring for the connected factory
Gearboxes equipped with cynapse® functionality from WITTENSTEIN alpha leverage advanced sensors and IO-Link connectivity to monitor parameters such as temperature, vibration, acceleration and mounting position in real time. Continuous analysis of operating conditions enables early detection of anomalies, reducing the risk of unexpected failures; the definition of customisable thresholds for key parameters; and the activation of predictive alerts in the event of deviations from set values.
Greater efficiency and reduced operating costs
The integration of collected data makes it possible to optimise maintenance interventions, delivering tangible benefits for companies – from reduced component wear and extended service life to fewer unplanned stoppages, with a positive impact on overall production efficiency. This is complemented by lower repair costs, thanks to targeted and timely maintenance, and improved energy sustainability resulting from the intelligent management of operating parameters. Finally, gearboxes featuring cynapse® maintain the same dimensions and design characteristics as standard versions, allowing for plug-and-play installation without the need for structural modifications.
