Client
Project Overview
We delivered a vibration monitoring solution for Mahindra & Mahindra's Rudrapur plant, using Hansford accelerometers feeding a 4–20mA signal into PLC and SCADA. The system tracks vibration levels across 28 motors against predefined setpoints, triggering alarms and logging historic trends to catch bearing wear before it causes a breakdown.
High-mounted blower and other higher-rating motors — like those in the paint booth — often sit where routine physical inspection isn't practical. Left unchecked, a misaligned motor or a worn belt drives up vibration, which raises motor current and leads to premature bearing failure. At Mahindra & Mahindra's Rudrapur plant, the requirement was to catch that wear early, across 28 motors, without needing someone to climb up and check each one.
Hansford accelerometers were installed on each motor, converting vibration into a scaled 4–20mA signal fed to the PLC's analog input — the same interface used for loop-powered sensors built for PLC, BMS, and SCADA integration. SCADA compares real-time vibration readings against predefined setpoints for all 28 motors, and stores historic trend data alongside the live values.
Alarms fire when a motor's vibration crosses its setpoint, and historic trends let the maintenance team spot a slow drift toward failure rather than reacting only after a bearing has already gone. That shift — from unplanned breakdown to predictive maintenance — is the core value of the setup.
28 motors across the Rudrapur plant are now watched continuously for the vibration signature that precedes bearing failure, with alarms and trend data replacing manual inspection on equipment that was hard to reach in the first place.
Tell us what runs manually today and what it costs you. A senior engineer — not a sales team — will look at your scope and give you a straight technical answer: what we'd build, how long it takes, and what it's likely to cost. If we're not the right fit, we'll tell you that too.