Real-time condition monitoring for extreme industrial environments
2M Engineering develops OEM-ready sensor platforms for condition and wear monitoring in harsh industrial environments. Our solutions enable continuous, real-time insight into critical mechanical wear processes that were traditionally inaccessible during operation.
A proven example of this platform approach is RSens™, an industrial wear monitoring solution developed, certified, and produced by 2M Engineering and commercialised by Howden Thomassen Compression Systems. RSens™ demonstrates how advanced sensing, robust packaging, certification expertise, and industrialisation come together in a scalable OEM solution.
From periodic inspection to continuous condition monitoring
The challenge
In many industrial systems—such as reciprocating compressors—critical wear components can only be inspected during shutdown. Preventive maintenance typically relies on:
- Manual inspection after opening the machine
- Conservative maintenance intervals
- Limited insight into actual wear progression
- Increased downtime and safety risks
Real-time measurement inside an operating compressor was long considered impractical due to extreme pressure, temperature, vibration, and aggressive media.
The platform solution
2M Engineering developed a robust in-situ wear monitoring platform that enables continuous measurement inside operating machinery.
In the RSens™ implementation, an eddy-current distance sensor is integrated into the cylinder head end-cover, allowing real-time measurement of piston position relative to the cylinder liner. This provides highly accurate insight into rider ring wear while the compressor remains fully operational.
The underlying platform architecture is applicable to a wide range of industrial condition monitoring use cases where precision distance or wear measurement under extreme conditions is required.
Key platform characteristics
- In-situ measurement inside operating machinery
- Micron-level accuracy (≈50 µm) under dynamic conditions
- Designed for extreme pressure, temperature, vibration and chemicals
- Continuous, real-time data output for condition-based maintenance
- Compatible with standard industrial interfaces (e.g. 4–20 mA)
- Designed for certification, production, and long-term field deployment
Precision data for predictive maintenance
Accurate condition data is essential for optimising maintenance strategies in continuously operating assets.
For components such as piston rider rings, timing is critical:
- Replacing too early leads to unnecessary cost and waste
- Replacing too late risks severe damage and unplanned downtime
By providing continuous wear measurements, this platform enables true predictive maintenance:
- Maintenance at the optimal moment
- Reduced service costs
- Increased uptime and operational safety
In operational deployments, this approach has proven to pay for itself through avoided downtime and improved asset reliability.
Proven implementation: RSens™ wear monitoring system
RSens™ is a certified implementation of the 2M industrial wear monitoring platform, developed and industrialised in close collaboration with an OEM partner.
RSens™ highlights
- Real-time wear measurement inside gas and oil compressors
- Patented sensing technology
- ATEX certified for explosion zone 0 (T1–T4)
- Designed, certified, and produced by 2M Engineering
Technical overview (RSens™ implementation)
Sensor
- Measuring range: 0.3 – 3.0 mm
- Resolution: ~50 µm
- Design pressure: 250 bar
- Test pressure: 350 bar
- Operating temperature: −60 °C to +150 °C
- Certification: Ex II 1G Ex ia IIC T4
Signal processing unit
- Output: 4–20 mA
- Supply voltage: 24 V DC
- Operating temperature: −40 °C to +60 °C
- Shock resistance: 100 g (IEC 68-2-27)
- Vibration resistance: 5 g / 10–150 Hz (IEC 68-2-6)
- ATEX certified (zones 0 and 1)
Beyond compressors: a reusable OEM platform
While RSens™ is deployed in petrochemical compressor systems, the underlying platform is applicable to many other industries, including:
- Power generation
- Heavy machinery
- Process industry
- Energy and hydrogen systems
- Safety-critical rotating equipment
Anywhere precise distance, position, or wear must be measured reliably under extreme conditions, this platform can be adapted and customised.
OEM development, certification & production
2M Engineering supports OEM partners throughout the full lifecycle:
- Sensor concept & feasibility
- Custom sensing principles & packaging
- ATEX and industrial certification
- Industrialisation and series production
- Transfer to OEM manufacturing if required
RSens™ demonstrates how a complex sensing challenge can be translated into a certified, field-proven, and commercially successful OEM solution.
Interested in condition monitoring for your application?
The RSens™ platform is one example of how 2M Engineering enables next-generation industrial sensing solutions. We work closely with OEMs to develop custom condition and wear monitoring platforms tailored to specific assets and environments.
→ Contact 2M Engineering to explore how this platform approach can be applied to your system
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