The industrial internet of things (IIoT) and Industry 4.0 are already unleashing enormous value in plants around the world. It seems that today’s younger, digital workforce is the energy that propels this change. Past efforts had been sluggish to say the least.

Modern consumer products have put connected devices in our pocket, on our wrist, in our ears, in our car and throughout our home. IoT is projected to deliver between $1.9 and $4.7 trillion of economic value by 2025. The IIoT for asset monitoring is expected to produce $200-$500 billion in economic value by 2025. Condition-based maintenance (CBM), involving real-time sensing and predictive maintenance, is viewed as the “easy win” among all IIoT applications. Many new online sensors are being introduced each year (see Figure 1).

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The advent of unattended sensor technologies has placed a particular challenge on data communication for machine surveillance monitoring. This challenge is magnified when mobile equipment and large geographic territories are involved. The use of satellite communications has recently been applied in an extensive condition-based maintenance program for a large fleet of railroad maintenance equipment. The satellite communications. are a part of an integrated system of sensor, software and communications technologies.

This paper describes the selection and application of sensors for the real-time monitoring of contamination in hydraulic fluid and engine oil. Also discussed will be onboard data collection electronics, onboard satellite transmission hardware and knowledge-based data analysis and exception reporting. The paper will be presented as a case study, and is believed to be the first of its kind for condition-based maintenance employing satellite communications technology.

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