Condition monitoring

CoMoSens – Sensor und rechts daneben ist unscharf eine Person mit Helm zu erkennen.

Methods and measuring systems for condition monitoring (CM) ensure the availability of plants and machinery. The regular collection of machine conditions and states can provide decisive information needed for maintenance, repair and operations (MRO) strategies, for better control and optimized processes. Static components, by contrast, can be monitored automatically with structural health monitoring (SHM). SHM detects and assesses damage mechanisms and ensures the reliability and optimal function of critical components.

Improved reliability, reduced costs

Fraunhofer IKTS is a competent partner when it comes to monitoring materials, components, assemblies, plants and machinery as well as the pertaining manufacturing methods. This includes the analysis and assessment of components and processes, as well as their optimization.

For this purpose, IKTS develops sensors (optical, acoustic, electromagnetic), systems and techniques for condition monitoring, which are implemented while plants are being built and taken into operation. These systems can also be installed in existing infrastructures. They are designed for harsh conditions and offer tools for the non-destructive detection of defects, real-time monitoring and, associated with this, condition-based maintenance or optimization of plants.

The customized solutions help to improve plant safety in full compliance with all standards. They are developed in close cooperation with machine manufacturers and users.




Every CM system is unique: Corrective, informative or predictive – only a customized maintenance strategy will lead to a longer service life and cost savings. CM systems by Fraunhofer IKTS focus on identifying, recording and assessing  the  decisive parameters. The intelligent systems may predict damage based on probabilities, increasing the availability of plants and components.


Manufacturing industry

Manufacturing processes are the main focus of operational performance. They decide on a company’s competitive advantage. With its process know-how, Fraunhofer IKTS contributes to the design of efficient and safe manufacturing processes in many branches of the industry. The core area is the fast, contactless monitoring of materials, components and whole plants using acoustic and optical test methods.


Energy sector

Safety and reliability are essential for large-scale plants. Monitoring of critical components, such as rotor blades or pipes, helps to prevent downtime and reduce maintenance costs. Fraunhofer IKTS offers various systems for the condition monitoring of onshore and offshore plants. Furthermore, IKTS is available as a service provider for supporting fatigue tests and for instrumentation, operation and the evaluation of measuring results.



Passenger and cargo volumes are growing globally. This means increased requirements for efficient monitoring systems, which must provid the highest possible level of safety. Fraunhofer IKTS develops such systems and services for the condition monitoring of components. They allow for recognizing damages in real time and repair it at an early stage to avoid serious consequential damage.


Bio- and medical technology

For the pharmaceutical and food industries, proving the purity of products and raw materials is an essential task. Fraunhofer IKTS transfers and implements the latest acoustic and optical diagnostic methods for industrial applications in systems for condition monitoring in bio- and medical technology. The aim is to increase quality standards without affecting standardized processes and procedures.


Technical equipment

  • Multi-channel acoustic measurement system MAS
  • AMSY-6 acoustic emission testing system and software by Vallen Systeme GmbH
  • Radio node
  • Polymer optical acoustic emission system
  • Leica ScanStation C5

Cooperation models

Innovation and development are the cornerstones of a promising corporate future. In order to create a competitive edge, Fraunhofer offers tailored options for cooperation, so that companies can work together in the best possible way. This also allows to utilize development skills at short notice and as needed.