SEW-EURODRIVE is advancing industrial efficiency through its DriveRadar® IoT Suite, a predictive maintenance system designed to minimize equipment downtime, reduce maintenance costs, and optimize energy consumption. This technology leverages AI-driven models to create digital twins of industrial equipment, enabling early detection of deviations from normal operating behavior. The system collects data directly from SEW-EURODRIVE frequency inverters, measuring key operational parameters such as time of operation, energy consumption, load, torque, and detecting vibrations or shocks.
The DriveRadar® IoT Suite addresses growing demand across industries for intelligent asset management and real-time operational insights. Willem Strydom, Business Development Manager for Electronics at SEW-EURODRIVE, notes that organizations require comprehensive, instantaneous information about their processes. The platform integrates intelligent sensors, edge computing, and cloud analytics to provide complete visibility into operational environments, moving beyond conventional maintenance practices.
Traditional maintenance approaches, such as periodic manual inspections, prove inadequate for modern production settings. Werner Engelbrecht, Works Manager at Megatronic within SEW-EURODRIVE, points out that conventional surveys often become outdated as equipment is replaced or repaired. DriveRadar® automatically registers new components, maintaining a dynamic and accurate inventory of all assets. This continuous accuracy is crucial for informed decision-making as production environments undergo modifications.
The core value of DriveRadar® lies in its predictive capabilities, which prevent catastrophic equipment failures. By acting on the system’s analytical insights, operators can avert complete breakdowns, reducing the need for extensive physical inspections. This allows maintenance teams to focus on more strategic and high-value activities.
A key differentiator of DriveRadar® is its reliance on SEW-EURODRIVE’s integrated drivetrain infrastructure rather than external sensor technologies. Strydom explains that the company’s frequency inverters serve as advanced sensing instruments, continuously gathering data on operational duration, energy consumption, mechanical load, torque, and vibrations or shocks. Each device generates hundreds of measurable parameters, providing granular visibility into equipment performance.
When augmented with dedicated motor sensors and specialized vibration measurement equipment, DriveRadar® captures a broader spectrum of data, including thermal readings, environmental factors, lubricant levels, indicators of component degradation, load fluctuations, and vibration characteristics derived from motor harmonic analysis.
This extensive data collection enables the creation of a digital twin of each drivetrain system. Artificial intelligence algorithms establish a baseline of normal operational behavior from the outset. The system then identifies any deviations from this baseline, enabling early detection of bearing deterioration, estimation of brake component lifespan, scheduling of maintenance, identification of mechanical defects, and recognition of operational inefficiencies. DriveRadar® can also extend monitoring to non-SEW-EURODRIVE equipment, making it applicable to entire systems, including conveyor networks and automated assembly machinery.
The platform’s operational accessibility is another significant advantage. DriveRadar® offers flexible data storage options, including SEW-EURODRIVE-managed cloud repositories, private cloud infrastructure, or on-premises servers. It integrates seamlessly with existing SCADA frameworks. Maintenance personnel can access comprehensive equipment information and generate analytical reports using mobile devices, even in remote locations, through GSM or SIM card communication protocols. This immediate access allows for instantaneous detection of emerging issues without physical site visits.
Recognizing the importance of effective technology adoption, SEW-EURODRIVE has invested significantly in comprehensive training programs. These initiatives, delivered both at customer facilities and through the specialized Drive Academy in Johannesburg, ensure that organizations are equipped to implement and maximize the benefits of these advanced predictive maintenance technologies. The system’s ability to create a digital twin using AI-driven models to detect deviations from normal operating behavior, as reported by African Mining African Mining, underscores its advanced capabilities. Furthermore, African Mining details how DriveRadar® collects data from SEW-EURODRIVE frequency inverters, measuring crucial operational metrics African Mining.
Sources
- https://www.africanmining.co.za/2026/01/21/sew-eurodrive-advances-industrial-performance-with-next-gen-predictive-maintenance/
