European researchers are hard at work developing wireless sensors that will predict when components will fail. The implication of such a sensor has broad implications for just about all sectors of the manufacturing industry. The sensor could theoretically reduce machinery breakdowns to zero and significantly reduce maintenance costs. The research is being performed at the University of Manchester in the United Kingdom, as part of a $7 million initiative funded by the European Union.

Once fitted, the sensors would remotely monitor of the health of parts and use the data to determine when they need maintenance or replacement. One type would measure vibration, temperature and pressure, while another type would be installed inside lubricated machinery to measure concentrations of metallic elements created through sustained use.

“By monitoring the condition of major parts we will be able to predict when they require maintenance and when they need replacing before they fail,” says Andrew Starr, a University of Manchester researcher. “This will dramatically reduce the delay and cost caused by impromptu breakdowns, and we hope it will also lead to a much more efficient service for customers.”

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