Predictive Maintenance

Predictive maintenance by means of structure-borne sound analysis


Due to long start-up times and the need for on-site diagnostics, defects in widely distributed, decentralized systems have a severe impact on operational processes. Therefore, redundant systems are often used, which are associated with high investments.

With the help of continuous monitoring of operating data as well as structure-borne noise analysis, SYS TEC electronic enables the plant operator to detect wear or contamination on the machines before they fail, thus realizing predictive maintenance and minimizing downtime without having to use expensive redundant resources.


    The solution for Predictive Maintenance is developed by SYS TEC electronic in cooperation with Bacsoft. In this method, the vibrations of rotating or vibrating components are recorded and analyzed using Fast Fourier Transformation (FFT). In this way, incipient wear and tear, loosening of mechanical connections or the penetration of foreign bodies can be detected at an early stage.

    These data are recorded as signals by structure-borne sound microphones or acceleration sensors placed at neuralgic points on the machine. A signal transformation from the time domain to the frequency domain enables the machine noise to be broken down into individual frequencies. This enables conclusions to be drawn about various wear and damage patterns. The resulting frequency spectrum can be automatically evaluated using intelligent software. By storing threshold values, warning messages and alarms can be generated automatically.

    The structure-borne sound analysis is technically realized by three main components: our industrial controllers of the sysWORXX brand, the extension module for FFT and the IoT platform of the company Bacsoft.

    The extension module provides the signals of the structure-borne sound sensors as digitally processable data to the main controller. It thus enables the analysis and evaluation of the vibration data. An analysis of up to six channels simultaneously is possible. This corresponds to the motion data in the three spatial axes at two measuring points. The transformation and filter algorithms used are flexible and can be adapted to individual customer requirements.

    The Bacsoft platform is an end-to-end solution for designing and managing advanced IIoT and M2M applications. Bacsoft provides the expertise to integrate the sysWORXX hardware and deliver a cloud-based application for remote monitoring and control of operations.

    The solution can be combined with other standard sensors and actuators (e.g. temperature, humidity, ...) to obtain an overall picture of the plant condition. Thus, the machine analysis on plants of different ages can be extended, for example, also with regard to energy monitoring.

    Do you have a similar challenge?

    We would be happy to develop an individual solution for you based on our existing know-how. Please contact us. We will be happy to advise you.

    Technical parameters

    The extension module to the FFT, developed for the operator of plants in the field of conveyor technology, has the following specifications:

    • 6 channels
    • Sensors: IEPE acceleration sensors (Integrated Electronics Piezo Electric)
    • Resolution: 16 bit
    • Sampling rate: 2.5 kHz
    • useful signal bandwidth: 3 ... 1000 Hz
    • FFT resolution: 3268 spectral lines with a resolution of 0.305 Hz
    • RMS: continuous RMS value
    • Temperature range: -20 ... +60 °C
    • Sensor diagnostics for each channel (short circuit/lead break)
    • Interfaces for value transfer (FFT data and RMS values): RS232 and Ethernet

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    Your SYS TEC electronic sales team

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