Condition monitoring is the continuous collection and analysis of machine data—such as temperature, vibration, or pressure—to detect wear before it leads to unplanned downtime. With TURCK, condition monitoring operates independently of process control: Data is collected directly at the machine, analyzed locally, and made available via MQTT or OPC UA—without interfering with the PLC program.
Unplanned downtime often begins with small anomalies: rising temperatures, unusual vibrations, moisture, pressure changes, or declining process stability. TURCK's condition monitoring makes these signals visible before they lead to failures.
Condition monitoring provides the data foundation on which the other two concepts are based. The three terms are often used interchangeably, but they address different questions.
In short: Condition monitoring detects the condition of a system, condition-based maintenance uses that information to determine when maintenance is needed, and predictive maintenance forecasts when a failure will occur.
Availability is one of the three factors that make up Overall Equipment Effectiveness (OEE), along with performance and quality. Any unplanned downtime directly reduces it.
Wear, contamination, overheating, and mechanical stress rarely occur without warning. A bearing that eventually fails usually shows signs of increasing vibration and temperature beforehand. A filter that becomes clogged causes a change in pressure. Such early warning signs are often already evident in sensor readings, in IO-Link device diagnostics, or in the condition of the control cabinet. TURCK transforms this information into actionable condition data for maintenance teams, enabling them to take action before a minor deviation leads to a shutdown.
Condition monitoring and process control are two separate functions, but they can be based on the same sensor data. Many field devices also provide their own diagnostic information. Sensor, I/O, and edge components from TURCK collect this data, preprocess it locally, and forward only relevant status information via open interfaces such as MQTT and OPC UA—to TAS Cloud, other IT systems, or a third-party cloud.
IO-Link devices provide process values cyclically and acyclic diagnostic information, such as device status, operating hours, or internal status values. In many applications, these existing data sources are sufficient for condition monitoring. Even standard sensors become a source of condition data when connected to a suitable fieldbus or I/O station.
TURCK’s IP67 IO-Link masters and multiprotocol I/O modules read process and diagnostic data directly from the machine. The modules support PROFINET, EtherNet/IP, Modbus TCP, and EtherCAT, and can therefore be integrated into virtually any control environment. Status data is captured in parallel with control data traffic without the PLC having to forward it.
Instead of a constant stream of raw data, meaningful status values are generated at the edge. TAS Edge or the ARGEE Field Logic Controller in the I/O module filter, aggregate, and evaluate the data—for example, by applying limit values, calculating averages, or analyzing trends. This keeps the network load low, and only relevant deviations are reported.
The preprocessed status data is sent via MQTT or OPC UA to its destination: TAS Cloud, an MES, a maintenance system, or a third-party cloud. The transmission runs independently of the PLC cycle and can be configured without programming.
TAS Cloud turns condition data into specific maintenance actions. Role-based dashboards display trends and machine status; intelligent alerts notify the appropriate personnel as soon as defined conditions are met; and maintenance features support structured tracking. This enables teams to shift from reactive troubleshooting to planned, data-driven maintenance—early enough to prevent downtime and late enough to avoid replacing components unnecessarily.
Relevant condition data includes, for example, temperature, vibration, humidity, pressure, flow, energy consumption, operating hours, switching cycles, and device diagnostics. Which of these are important depends on the types of failures in your application. Start with values that IO-Link devices and standard sensors already provide, and add specialized measurements only where they offer clear added value.
Whether you collect status data directly at the machine (IP67) or centrally in the control cabinet (IP20), TURCK offers suitable system solutions for both installation locations.
The cabinet guards in the IMX12-CCM family monitor key control cabinet parameters such as temperature, humidity, and door status. The IM18-CCM45 functions as a mini Linux PC inside the control cabinet, processes data from external sensors, and displays it in configurable dashboards—no programming knowledge required. For modular systems in the control cabinet, the BL20 I/O system acquires signals and, with the energy measurement module, also collects consumption data.
IP67 block I/O modules such as TBEN and Edge-enabled controllers collect status data directly at the machine, without the need for a control cabinet. With ARGEE, TURCK’s browser-based field logic, you can implement actions locally within the I/O module—ranging from simple limit monitoring to more complex logic functions. For example, the module can directly trigger a visual or audible alarm or send a warning to higher-level systems without placing a load on the PLC or network.
The TURCK Automation Suite (TAS) consists of four modules. For condition monitoring, TAS Edge and TAS Cloud work together primarily, supplemented by TAS Desktop and TAS Mobile for commissioning and on-site access.
Capture, filter, and organize condition data at the source. Configurable no-code and low-code workflows reduce the data volume, identify relevant anomalies, and establish connections between machine data and MQTT, OPC UA, or cloud services.
Visualize status trends in role-based dashboards, define alerts, and grant teams access to machine information. Establish connections between data sources and IT systems without programming—as the foundation for remote service and digital service models.
Manage devices locally, standardize configurations, and make the commissioning process repeatable. Mass configuration and structured rollouts ensure traceability across machines and projects.
Access relevant device information directly in the field using your smartphone or tablet. Mobile features speed up diagnostics, device replacement, and configuration at the machine, thereby reducing downtime.
TURCK's condition monitoring is suitable for both new machines and existing systems. Because condition data is processed independently of the actual control task, the same approach works for both scenarios.
For existing systems, condition data from installed sensors and IO-Link devices can be collected without rewiring the machine or modifying the PLC application. This is ideal for retrofit projects where changes should be kept to a minimum.
For new machines, monitoring functions can be integrated directly into the automation architecture, making status data, edge processing, and cloud connectivity an integral part of the machine design. This is ideal for machine builders who want to offer digital services to their customers.
"I need to respond quickly to malfunctions—but I don't have access to the control system."
Solution: Status data is transmitted via TAS Edge separately from the PLC. Intelligent alarms in TAS Cloud report deviations in real time, and TAS Mobile provides access directly at the device.
"I need reliable figures on availability—not just after the downtime."
Solution: Dashboards in TAS Cloud show the status of all monitored machines at a glance. Trends highlight where a failure is imminent, and maintenance can be scheduled during planned downtime.
"I want to offer my customers digital Services without having to overhaul my control system."
Solution: Condition monitoring is integrated as a separate layer alongside the control system. Through TAS Cloud, you can remotely access your machines in the field and offer data-driven Service and maintenance contracts.
"I need a solution that works in a variety of customer environments."
Solution: multiprotocol I/O modules and open interfaces such as MQTT and OPC UA connect status data to any control and IT environment. TAS Desktop standardizes configurations across projects.
Learn how users in intralogistics, automotive manufacturing, and production are implementing condition monitoring with TURCK: including the specific challenges, data sources, system architecture, and results.
Talk to our experts
You don't need to redesign your machine for condition monitoring. By talking with our experts, you can determine what data is already available, which deviations are truly significant for your operations, and what your process looks like—from field data all the way to maintenance actions.
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What is condition monitoring?
Condition monitoring is the continuous collection and analysis of machine data such as temperature, vibration, pressure, or equipment diagnostics. The goal is to detect wear and deviations early on and prevent unplanned downtime. Condition monitoring provides the data foundation for predictive maintenance.
What is the difference between condition monitoring and predictive maintenance?
Condition monitoring tracks a machine's current condition and flags any deviations. Predictive maintenance goes a step further and uses condition trends to predict when a component is likely to fail. Without condition monitoring, there is no data for predictive maintenance.
Do I need additional sensors for condition monitoring?
In many cases, no. In addition to process values, IO-Link devices also provide diagnostic data such as device status or operating hours, and standard sensors can also serve as data sources when connected to a compatible I/O station. Additional sensors—such as those for vibration—are worthwhile in situations where a specific type of failure would otherwise go undetected.
Does condition monitoring require reprogramming the PLC?
No. At TURCK, status data runs separately from the process control: I/O modules and edge components collect and process it in parallel with the PLC. The PLC application remains unchanged, which is particularly important for existing systems.
Can I retrofit condition monitoring to existing systems?
Yes. Condition data can be collected from existing sensors and IO-Link devices without rewiring the machine or modifying the PLC. This makes TURCK’s approach suitable for both retrofit projects (brownfield) and new machines (greenfield).
What types of data are suitable for condition monitoring?
Typical condition data include temperature, vibration, humidity, pressure, flow, energy consumption, operating hours, switching cycles, and equipment diagnostics. Which of these are relevant depends on the types of failures specific to the application. A good place to start is with the data that existing equipment already provides.
What interfaces does TURCK use to transmit status data?
TURCK transmits status data via open interfaces such as MQTT and OPC UA. The destination can be the TAS Cloud platform, an MES, a maintenance system, or a third-party cloud. In the field, the multiprotocol I/O modules work with PROFINET, EtherNet/IP, EtherCAT and Modbus TCP.
What is ARGEE?
ARGEE is TURCK’s browser-based programming environment for field logic directly within the I/O module. It allows users to monitor limit values, trigger alarms, or preprocess data without placing a load on the PLC or network. For condition monitoring, this means that the I/O module responds to deviations on its own.
When is condition monitoring best performed in the control cabinet, and when in the field?
In the control cabinet (IP20), you can monitor the environment surrounding the control systems—such as temperature, humidity, and door status—using, for example, the cabinet guards from the IMX12-CCM family. In the field (IP67), block I/O modules such as the TBEN collect status data directly at the machine, without a control cabinet. Many systems combine both approaches.
What is the TURCK Automation Suite (TAS)?
The TURCK Automation Suite is a software platform consisting of four modules: TAS Edge for local data processing, TAS Cloud for dashboards, alarms, and remote service, TAS Desktop for device and project management, and TAS Mobile for on-site diagnostics. TAS Edge and TAS Cloud work together primarily for condition monitoring.
