Pizza oven production lines
Heavy-duty gearboxes on the pizza ovens are critical to production. WearDetect was installed to provide essential real-time insight into the health of the oven gearboxes
Oil debris sensors, continuously monitoring ferrous wear
- Earliest maintenance warnings protect critical assets
- Easy to install and straightforward to interpret results
- Reduces unplanned downtime
- Data platform option provides alerts and data visualisation
Oil debris sensors, continuously monitoring ferrous wear
- Earliest maintenance warnings protect critical assets
- Easy to install and straightforward to interpret results
- Reduces unplanned downtime
- Data platform option provides alerts and data visualisation
WearDetect oil debris sensors have been proven in use by world-leading manufacturers, to provide the earliest warning of the initial stages of machine failure. WearDetect is primarily used in oil based systems, such as gearboxes, across manufacturing and also by operators of critical and remote equipment. WearDetect can be used for stand-alone measurement, integrated into a larger PLC or SCADA system or used with Gill’s IoT platform for data collection, visualisation and alerts.
Key Features
- Real-time, continuous condition monitoring
- Captures and measures both fine & coarse ferrous wear debris
- Proven high return on investment by minimising unplanned downtime
- WearDetect sensor data can be used to predict and schedule maintenance actions
- Oil temperature or water presence measurement
- No expert knowledge or training required to interpret results
- Multiple thread adaptor options for easy installation
- Data platform option provides insight into equipment health, straight to your device
Typical Applications
- Wind turbine condition monitoring
- Automotive manufacturing
- Industrial processes including paper & chemicals
- Conveyor drives within distribution facilities
- Condition monitoring in mining industries
- Crane gearbox monitoring
WearDetect technical information
-
PRODUCT RANGE
-
Oil Debris Sensor with Display
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
- Local indicator display
Oil Debris Sensor
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
Oil Debris Sensor + IoT
- Remote asset monitoring with alerts
- Data collection, visualisation and analysis
- One simple-to-use platform
- Scalable - add sensors to the platform
Starter kit
- Protect 2 critical assets with everything needed to get started
- No complicated training - just watch the video
- Free global delivery
WearDetect, oil debris sensors for continuous ferrous wear monitoring - more details
Designed & Manufactured by Gill Sensors & Controls in the UK, WearDetect oil debris sensors provide condition based monitoring that protects critical rotating assets by directly measuring ferrous wear within the equipment.Â
WearDetect provides an earlier view of wear trends in vital equipment. The sensor replaces the existing drain plug and wires into your existing PLC or SCADA system or Gill’s IoT platform. Alternatively, an ‘inflow’ adaptor arrangement can be used to install the sensor in the oil flow line, before any filters. The sensor captures and measures fine wear and coarse failure ferrous particles in order to allow machine wear trend insights.
Output protocol options for WearDetect include digital outputs (Modbus and CAN) or analogue outputs (0-10V or 4-20mA). There is also a local visual alarm option. The sensors are designed to suit most data collection devices such as dataloggers, PLCs and ECUs as well as Gill’s own IoT data platform.Â
WearDetect sensors have no moving parts and as a result are extremely reliable and accurate.Â
-
DOWNLOADS
-
WearDetect Brochure
Wear Debris Monitoring on Low Speed Drives
An introduction to Wear Debris Monitoring in the industrial marketplace
WearDetect User Manual
WearDetect QuickStart Guide
WearDetect Starter Kit QuickStart Guide
-
ACCESSORIES
-
WearDetect Accessories
WearDetect oil debris sensors can be supported by accessories to assist with specific installation requirements.
WearDetect thread adaptors
Gill offer a range of thread adaptors for metric, NPT, BSP & UNF drain port types. Plug the WearDetect sensor into the sump using the relevant adaptor.
Inflow adaptor kit
An ‘inflow’ adaptor kit can be constructed using standard components to allow the WearDetect oil debris sensor head to be installed at a convenient position within the lubrication bypass circuit of the equipment. The inclusion of valves facilitates easy sensor inspection with minimal oil loss.Â
Â
Inflow adaptor
An off-the-shelf ‘inflow’ adaptor will allow installation of the WearDetect, oil debris sensor probe at a convenient position within the lubrication bypass circuit of the equipment.Â
-
VIDEOS
-
WEBINARS
-
Webinars
The webinars are available to download and watch on-demand.
Continuous oil debris monitoring – why the world’s largest manufacturers have taken it on board.Â
This webinar provides information on continuous oil debris monitoring as an effective addition to a condition based monitoring (CBM) portfolio. This new approach to CBM allows earlier awareness of mechanical damage and maintenance needs, especially in scenarios such as variable load gearboxes and low speed systems where other techniques struggle to identify problems before it’s too late.
 (45 mins)
WEBINAR: Predicting asset failures sooner in automotive manufacturing lines
Wear debris monitoring in machinery lubricants is becoming a key part of condition based monitoring (CBM) in automotive production environments.
This webinar provides information on how continuous oil debris monitoring is being used in automotive production to provide earlier awareness of equipment wear and maintenance needs especially in assets such as conveyor gearboxes and machine tool multi-spindle gearboxes, where other techniques struggle to identify problems in time for corrective action.Â
-
SOFTWARE
-
WearDetect Software
Overview
WearDetect oil debris sensors can be installed ‘out of the box’. However, to adjust the sensor parameters, please download the WearDetect software here. Please see the ‘WearDetect installation & optimization’ video in the VIDEOS tab.Â
Compatible Products
WearDetect oil debris sensorsAdditional applications to support Gill products
Gill has a number of applications to support older products and older operating systems. For more information please contact support@gillsc.com specifying
- Product name
- Part number
- Product serial number
- PC operating system
-
FURTHER RESOURCES
-
Application notes
Read More
Oil Debris Sensor prevents mechanical breakdown of speed reducer
Read MoreOil debris sensor detects early signs of component breakdown in speed reducer. Vibration monitoring techniques had proven insufficient to prevent downtime
Oil condition monitoring in wind turbines
Read MoreOil debris sensors are a powerful multi-point predictive maintenance tool providing the earliest warning of ferrous wear in wind turbine gearboxes
Gearbox reliability for extrusion machines ​
Read MoreOil debris sensors improve gearbox reliability on extrusion machines, providing operators with a clear picture of the health of the extruder ​
Ferrous debris sensor with Modbus integrates into existing manufacturing and distribution systems
Read MoreHigh numbers of critical and highly loaded gearboxes in manufacturing plants or within conveyor drives in large scale distribution and warehousing facilities, benefit from ferrous debris sensors providing essential real-time insight into gearbox health. Outputs such as Modbus ensure these sensors can be readily integrated into existing systems.
Factsheets
Common causes of bearing failure in gearboxes
Read MoreGearbox failure can cause a complete machinery breakdown, expensive to repair as well as lost output. Common causes of bearing failure in gearboxes include…​
Oil Debris Sensor with Display
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
- Local indicator display
Oil Debris Sensor
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
Oil Debris Sensor + IoT
- Remote asset monitoring with alerts
- Data collection, visualisation and analysis
- One simple-to-use platform
- Scalable - add sensors to the platform
Starter kit
- Protect 2 critical assets with everything needed to get started
- No complicated training - just watch the video
- Free global delivery
WearDetect, oil debris sensors for continuous ferrous wear monitoring - more details
Designed & Manufactured by Gill Sensors & Controls in the UK, WearDetect oil debris sensors provide condition based monitoring that protects critical rotating assets by directly measuring ferrous wear within the equipment.Â
WearDetect provides an earlier view of wear trends in vital equipment. The sensor replaces the existing drain plug and wires into your existing PLC or SCADA system or Gill’s IoT platform. Alternatively, an ‘inflow’ adaptor arrangement can be used to install the sensor in the oil flow line, before any filters. The sensor captures and measures fine wear and coarse failure ferrous particles in order to allow machine wear trend insights.
Output protocol options for WearDetect include digital outputs (Modbus and CAN) or analogue outputs (0-10V or 4-20mA). There is also a local visual alarm option. The sensors are designed to suit most data collection devices such as dataloggers, PLCs and ECUs as well as Gill’s own IoT data platform.Â
WearDetect sensors have no moving parts and as a result are extremely reliable and accurate.Â
WearDetect Brochure
Wear Debris Monitoring on Low Speed Drives
An introduction to Wear Debris Monitoring in the industrial marketplace
WearDetect User Manual
WearDetect QuickStart Guide
WearDetect Starter Kit QuickStart Guide
WearDetect Accessories
WearDetect oil debris sensors can be supported by accessories to assist with specific installation requirements.
WearDetect thread adaptors
Gill offer a range of thread adaptors for metric, NPT, BSP & UNF drain port types. Plug the WearDetect sensor into the sump using the relevant adaptor.
Inflow adaptor kit
An ‘inflow’ adaptor kit can be constructed using standard components to allow the WearDetect oil debris sensor head to be installed at a convenient position within the lubrication bypass circuit of the equipment. The inclusion of valves facilitates easy sensor inspection with minimal oil loss.Â
Â
Inflow adaptor
An off-the-shelf ‘inflow’ adaptor will allow installation of the WearDetect, oil debris sensor probe at a convenient position within the lubrication bypass circuit of the equipment.Â
Videos
View our short videos to get an insight into how WearDetect works and how it delivers a high return on investment by minimising unplanned downtime.
WearDetect provides maintenance warnings earlier than any other condition monitoring product.Â
(2 mins)
WearDetect explained
How the sensor works and how to get the best from the sensor in order to protect an asset from unexpected failure.
(5 mins)
WearDetect Starter Kit training
Training video to be used with the WearDetect Starter Kit, summarising how the sensor works, how to install it and how to get the best from the sensor to protect critical assets.Â
(6 mins)
WearDetect installation video (short)
WearDetect oil debris sensors can be installed directly out of the box using factory settings to be up and running within a few minutes.Â
The video covers unboxing and oil debris sensor installation.Â
(1.5 mins)
WearDetect installation & optimization video
For more specific sitations or where you have been using WearDetect for some time and wish to tailor the output, WearDetect can be fully optimized to suit your specific application.
The video covers unboxing, oil debris sensor set up, configuration, calibration and installation.Â
(6.5 mins)
Webinars
The webinars are available to download and watch on-demand.
Continuous oil debris monitoring – why the world’s largest manufacturers have taken it on board.Â
This webinar provides information on continuous oil debris monitoring as an effective addition to a condition based monitoring (CBM) portfolio. This new approach to CBM allows earlier awareness of mechanical damage and maintenance needs, especially in scenarios such as variable load gearboxes and low speed systems where other techniques struggle to identify problems before it’s too late.
 (45 mins)
WEBINAR: Predicting asset failures sooner in automotive manufacturing lines
Wear debris monitoring in machinery lubricants is becoming a key part of condition based monitoring (CBM) in automotive production environments.
This webinar provides information on how continuous oil debris monitoring is being used in automotive production to provide earlier awareness of equipment wear and maintenance needs especially in assets such as conveyor gearboxes and machine tool multi-spindle gearboxes, where other techniques struggle to identify problems in time for corrective action.Â
WearDetect Software
Overview
WearDetect oil debris sensors can be installed ‘out of the box’. However, to adjust the sensor parameters, please download the WearDetect software here. Please see the ‘WearDetect installation & optimization’ video in the VIDEOS tab.Â
Compatible Products
WearDetect oil debris sensors
Additional applications to support Gill products
Gill has a number of applications to support older products and older operating systems. For more information please contact support@gillsc.com specifying
- Product name
- Part number
- Product serial number
- PC operating system
Application notes
Pizza oven production lines
Heavy-duty gearboxes on the pizza ovens are critical to production. WearDetect was installed to provide essential real-time insight into the health of the oven gearboxes
Oil Debris Sensor prevents mechanical breakdown of speed reducer
Oil debris sensor detects early signs of component breakdown in speed reducer. Vibration monitoring techniques had proven insufficient to prevent downtime
Oil condition monitoring in wind turbines
Oil debris sensors are a powerful multi-point predictive maintenance tool providing the earliest warning of ferrous wear in wind turbine gearboxes
Gearbox reliability for extrusion machines ​
Oil debris sensors improve gearbox reliability on extrusion machines, providing operators with a clear picture of the health of the extruder ​
Ferrous debris sensor with Modbus integrates into existing manufacturing and distribution systems
High numbers of critical and highly loaded gearboxes in manufacturing plants or within conveyor drives in large scale distribution and warehousing facilities, benefit from ferrous debris sensors providing essential real-time insight into gearbox health. Outputs such as Modbus ensure these sensors can be readily integrated into existing systems.
Factsheets
Common causes of bearing failure in gearboxes
Gearbox failure can cause a complete machinery breakdown, expensive to repair as well as lost output. Common causes of bearing failure in gearboxes include…​
-
PRODUCT RANGE
-
Oil Debris Sensor with Display
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
- Local indicator display
Oil Debris Sensor
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
Oil Debris Sensor + IoT
- Remote asset monitoring with alerts
- Data collection, visualisation and analysis
- One simple-to-use platform
- Scalable - add sensors to the platform
Starter kit
- Protect 2 critical assets with everything needed to get started
- No complicated training - just watch the video
- Free global delivery
WearDetect, oil debris sensors for continuous ferrous wear monitoring - more details
Designed & Manufactured by Gill Sensors & Controls in the UK, WearDetect oil debris sensors provide condition based monitoring that protects critical rotating assets by directly measuring ferrous wear within the equipment.Â
WearDetect provides an earlier view of wear trends in vital equipment. The sensor replaces the existing drain plug and wires into your existing PLC or SCADA system or Gill’s IoT platform. Alternatively, an ‘inflow’ adaptor arrangement can be used to install the sensor in the oil flow line, before any filters. The sensor captures and measures fine wear and coarse failure ferrous particles in order to allow machine wear trend insights.
Output protocol options for WearDetect include digital outputs (Modbus and CAN) or analogue outputs (0-10V or 4-20mA). There is also a local visual alarm option. The sensors are designed to suit most data collection devices such as dataloggers, PLCs and ECUs as well as Gill’s own IoT data platform.Â
WearDetect sensors have no moving parts and as a result are extremely reliable and accurate.Â
-
DOWNLOADS
-
WearDetect Brochure
Wear Debris Monitoring on Low Speed Drives
An introduction to Wear Debris Monitoring in the industrial marketplace
WearDetect User Manual
WearDetect QuickStart Guide
WearDetect Starter Kit QuickStart Guide
-
ACCESSORIES
-
WearDetect Accessories
WearDetect oil debris sensors can be supported by accessories to assist with specific installation requirements.
WearDetect thread adaptors
Gill offer a range of thread adaptors for metric, NPT, BSP & UNF drain port types. Plug the WearDetect sensor into the sump using the relevant adaptor.
Inflow adaptor kit
An ‘inflow’ adaptor kit can be constructed using standard components to allow the WearDetect oil debris sensor head to be installed at a convenient position within the lubrication bypass circuit of the equipment. The inclusion of valves facilitates easy sensor inspection with minimal oil loss.Â
Â
Inflow adaptor
An off-the-shelf ‘inflow’ adaptor will allow installation of the WearDetect, oil debris sensor probe at a convenient position within the lubrication bypass circuit of the equipment.Â
-
VIDEOS
-
WEBINARS
-
Webinars
The webinars are available to download and watch on-demand.
Continuous oil debris monitoring – why the world’s largest manufacturers have taken it on board.Â
This webinar provides information on continuous oil debris monitoring as an effective addition to a condition based monitoring (CBM) portfolio. This new approach to CBM allows earlier awareness of mechanical damage and maintenance needs, especially in scenarios such as variable load gearboxes and low speed systems where other techniques struggle to identify problems before it’s too late.
 (45 mins)
WEBINAR: Predicting asset failures sooner in automotive manufacturing lines
Wear debris monitoring in machinery lubricants is becoming a key part of condition based monitoring (CBM) in automotive production environments.
This webinar provides information on how continuous oil debris monitoring is being used in automotive production to provide earlier awareness of equipment wear and maintenance needs especially in assets such as conveyor gearboxes and machine tool multi-spindle gearboxes, where other techniques struggle to identify problems in time for corrective action.Â
-
SOFTWARE
-
WearDetect Software
Overview
WearDetect oil debris sensors can be installed ‘out of the box’. However, to adjust the sensor parameters, please download the WearDetect software here. Please see the ‘WearDetect installation & optimization’ video in the VIDEOS tab.Â
Compatible Products
WearDetect oil debris sensorsAdditional applications to support Gill products
Gill has a number of applications to support older products and older operating systems. For more information please contact support@gillsc.com specifying
- Product name
- Part number
- Product serial number
- PC operating system
-
FURTHER RESOURCES
-
Application notes
Pizza oven production lines
Read MoreHeavy-duty gearboxes on the pizza ovens are critical to production. WearDetect was installed to provide essential real-time insight into the health of the oven gearboxes
Oil Debris Sensor prevents mechanical breakdown of speed reducer
Read MoreOil debris sensor detects early signs of component breakdown in speed reducer. Vibration monitoring techniques had proven insufficient to prevent downtime
Oil condition monitoring in wind turbines
Read MoreOil debris sensors are a powerful multi-point predictive maintenance tool providing the earliest warning of ferrous wear in wind turbine gearboxes
Gearbox reliability for extrusion machines ​
Read MoreOil debris sensors improve gearbox reliability on extrusion machines, providing operators with a clear picture of the health of the extruder ​
Ferrous debris sensor with Modbus integrates into existing manufacturing and distribution systems
Read MoreHigh numbers of critical and highly loaded gearboxes in manufacturing plants or within conveyor drives in large scale distribution and warehousing facilities, benefit from ferrous debris sensors providing essential real-time insight into gearbox health. Outputs such as Modbus ensure these sensors can be readily integrated into existing systems.
Factsheets
Common causes of bearing failure in gearboxes
Read MoreGearbox failure can cause a complete machinery breakdown, expensive to repair as well as lost output. Common causes of bearing failure in gearboxes include…​
Oil Debris Sensor with Display
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
- Local indicator display
Oil Debris Sensor
- Real-time and continuous condition monitoring
- Communicates with DCS/PLC/CMMS or IoT systems
Oil Debris Sensor + IoT
- Remote asset monitoring with alerts
- Data collection, visualisation and analysis
- One simple-to-use platform
- Scalable - add sensors to the platform
Starter kit
- Protect 2 critical assets with everything needed to get started
- No complicated training - just watch the video
- Free global delivery
WearDetect, oil debris sensors for continuous ferrous wear monitoring - more details
Designed & Manufactured by Gill Sensors & Controls in the UK, WearDetect oil debris sensors provide condition based monitoring that protects critical rotating assets by directly measuring ferrous wear within the equipment.Â
WearDetect provides an earlier view of wear trends in vital equipment. The sensor replaces the existing drain plug and wires into your existing PLC or SCADA system or Gill’s IoT platform. Alternatively, an ‘inflow’ adaptor arrangement can be used to install the sensor in the oil flow line, before any filters. The sensor captures and measures fine wear and coarse failure ferrous particles in order to allow machine wear trend insights.
Output protocol options for WearDetect include digital outputs (Modbus and CAN) or analogue outputs (0-10V or 4-20mA). There is also a local visual alarm option. The sensors are designed to suit most data collection devices such as dataloggers, PLCs and ECUs as well as Gill’s own IoT data platform.Â
WearDetect sensors have no moving parts and as a result are extremely reliable and accurate.Â
WearDetect Brochure
Wear Debris Monitoring on Low Speed Drives
An introduction to Wear Debris Monitoring in the industrial marketplace
WearDetect User Manual
WearDetect QuickStart Guide
WearDetect Starter Kit QuickStart Guide
WearDetect Accessories
WearDetect oil debris sensors can be supported by accessories to assist with specific installation requirements.
WearDetect thread adaptors
Gill offer a range of thread adaptors for metric, NPT, BSP & UNF drain port types. Plug the WearDetect sensor into the sump using the relevant adaptor.
Inflow adaptor kit
An ‘inflow’ adaptor kit can be constructed using standard components to allow the WearDetect oil debris sensor head to be installed at a convenient position within the lubrication bypass circuit of the equipment. The inclusion of valves facilitates easy sensor inspection with minimal oil loss.Â
Â
Inflow adaptor
An off-the-shelf ‘inflow’ adaptor will allow installation of the WearDetect, oil debris sensor probe at a convenient position within the lubrication bypass circuit of the equipment.Â
Videos
View our short videos to get an insight into how WearDetect works and how it delivers a high return on investment by minimising unplanned downtime.
WearDetect provides maintenance warnings earlier than any other condition monitoring product.Â
(2 mins)
WearDetect explained
How the sensor works and how to get the best from the sensor in order to protect an asset from unexpected failure.
(5 mins)
WearDetect Starter Kit training
Training video to be used with the WearDetect Starter Kit, summarising how the sensor works, how to install it and how to get the best from the sensor to protect critical assets.Â
(6 mins)
WearDetect installation video (short)
WearDetect oil debris sensors can be installed directly out of the box using factory settings to be up and running within a few minutes.Â
The video covers unboxing and oil debris sensor installation.Â
(1.5 mins)
WearDetect installation & optimization video
For more specific sitations or where you have been using WearDetect for some time and wish to tailor the output, WearDetect can be fully optimized to suit your specific application.
The video covers unboxing, oil debris sensor set up, configuration, calibration and installation.Â
(6.5 mins)
Webinars
The webinars are available to download and watch on-demand.
Continuous oil debris monitoring – why the world’s largest manufacturers have taken it on board.Â
This webinar provides information on continuous oil debris monitoring as an effective addition to a condition based monitoring (CBM) portfolio. This new approach to CBM allows earlier awareness of mechanical damage and maintenance needs, especially in scenarios such as variable load gearboxes and low speed systems where other techniques struggle to identify problems before it’s too late.
 (45 mins)
WEBINAR: Predicting asset failures sooner in automotive manufacturing lines
Wear debris monitoring in machinery lubricants is becoming a key part of condition based monitoring (CBM) in automotive production environments.
This webinar provides information on how continuous oil debris monitoring is being used in automotive production to provide earlier awareness of equipment wear and maintenance needs especially in assets such as conveyor gearboxes and machine tool multi-spindle gearboxes, where other techniques struggle to identify problems in time for corrective action.Â
WearDetect Software
Overview
WearDetect oil debris sensors can be installed ‘out of the box’. However, to adjust the sensor parameters, please download the WearDetect software here. Please see the ‘WearDetect installation & optimization’ video in the VIDEOS tab.Â
Compatible Products
WearDetect oil debris sensors
Additional applications to support Gill products
Gill has a number of applications to support older products and older operating systems. For more information please contact support@gillsc.com specifying
- Product name
- Part number
- Product serial number
- PC operating system
Application notes
Pizza oven production lines
Heavy-duty gearboxes on the pizza ovens are critical to production. WearDetect was installed to provide essential real-time insight into the health of the oven gearboxes
Oil Debris Sensor prevents mechanical breakdown of speed reducer
Oil debris sensor detects early signs of component breakdown in speed reducer. Vibration monitoring techniques had proven insufficient to prevent downtime
Oil condition monitoring in wind turbines
Oil debris sensors are a powerful multi-point predictive maintenance tool providing the earliest warning of ferrous wear in wind turbine gearboxes
Gearbox reliability for extrusion machines ​
Oil debris sensors improve gearbox reliability on extrusion machines, providing operators with a clear picture of the health of the extruder ​
Ferrous debris sensor with Modbus integrates into existing manufacturing and distribution systems
High numbers of critical and highly loaded gearboxes in manufacturing plants or within conveyor drives in large scale distribution and warehousing facilities, benefit from ferrous debris sensors providing essential real-time insight into gearbox health. Outputs such as Modbus ensure these sensors can be readily integrated into existing systems.
Factsheets
Common causes of bearing failure in gearboxes
Gearbox failure can cause a complete machinery breakdown, expensive to repair as well as lost output. Common causes of bearing failure in gearboxes include…​