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Stand-alone monitoring system for dosing pumps

A step forward in the world of Industry 4.0
Stand-alone monitoring system for dosing pumps

The stand-alone monitoring system Maag Brain enables plant operators to monitor and control the performance of their pumps and all parameters relevant to the metering process. This development represents an important step into the world of Industry 4.0 and Internet of Things for the Swiss manufacturer. Originally developed for the micropumps of the DX series, the monitoring system can be used for Maag Group’s entire industrial portfolio.

By using optimised and modular material combinations, run-out tolerances and inlet geometries Maag pumps allow application specific solutions for the polymer, chemical, petrochemical, pharmaceutical and food industries. The portfolio includes the metering gear pumps of the Dosix series, which was recently extended with the DX 14 variants. The new gear pumps are even more powerful and are able to meet the growing demands of the industry in terms of low upstream pressure, high differential pressure and use for low-viscosity and/or corrosive media.

High-precision and low pulsation stainless steel Dosix gear pumps can be used, among other things, for dosing concentrated so-
lutions of flavours and fragrances in food, beverages or perfume. Optimised flavours consist of different concentrates that are typically mixed in very precise quantities. The quality and consistency of the final product depend on the exact quantities of the individual ingredients that go into the mixing process and are an important control variable. The shafts of stainless steel and slide bearings made of SiC, ZrO2 or synthetic carbon are used for thin liquid, aqueous and low-viscosity media assuring a high level of durability and performance.

Distillation extraction pumps for various distillation devices like thin film evaporators, short path evaporators or distillation plants are some of the other impor-
tant applications where Dosix pumps are used. Distillation processes need to be very precise to achieve the desired result. Low inlet pressure on the pumps puts high demands on extraction pumps: leak-tightness, low pressure loss at inlet, precision dosing of minimal volumetric flow.

Increasing efficiency with know-how

The Maag Brain stand-alone monitoring system has been developed to monitor pumps to ensure maximum efficiency during the operation. The performance of the pumps can be analysed and controlled with a dedicated and customisable algorithm, on site or remotely.

With Maag Brain, the customers can benefit from all the advantages related to the control of the functional parameters of the pump such as differential pressure, temperature, flow rate and vibration. It efficiently supports detection and performs any necessary maintenance to avoid downtime with potential loss of production.

Modular monitoring system

The Maag Brain is a modular and customisable system that allows monitoring the pressure, flow, temperature, speed of rotation of the motor and vibration at various points of the pumping system. Additional sensors can also be added according to the customer’s needs such as an additional temperature sensor on the pump housing or in the tank of the pumped fluid.

Once the operating parameters have been selected by the customer, the Maag Brain monitors them in real time and can be conveniently supervised remotely through a user-friendly, easy-to-read graphical interface. This results in the following advantages, among others:

  • The possibility of monitoring the inlet and discharge flow rate in real time, provides the advantage of evaluating possible malfunctions or inefficiencies in the process and intervene immediately to solve them.
  • Measuring the pressure at suction and
    discharge sides, allows to keep this vital parameter under control and to intervene in case of overpressure in delivery that can damage the pump and the systems downstream.
  • In order to have a predictive analysis of the state of wear of internal pump components, measuring vibration is the key. It can help prevent a reduction in volumetric efficiency or malfunction.

Like all mechanical equipment, the gear pump is characterised by a certain value of volumetric efficiency. This value is essential for Maag Group, which has made it a priority element in the construction of its pumps. With their new monitoring system the volumetric efficiency can be optimised automatically, taking full advantage of the mechanical qualities of the pumps.

The ability to monitor pump operating
conditions, on a regular basis, remotely and with an effective graphical interface, guarantees the user a reduction in maintenance costs and most importantly avoids costly downtime due to unexpected breakdowns.

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Online search: Maag


Author: Claudio Bonafede

Managing Director,

Maag Group Italy

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