Automated level control: coolant monitoring with the io-key
Efficient coolant monitoring on a power hacksaw
Goal of the project
In the manufacturing industry, particularly in metalworking, coolants are essential for reducing the frictional heat generated during forming and machining processes. On a power hacksaw, for example, the coolant ensures that the saw blade is adequately cooled and lubricated during the cutting operation.
However, monitoring the coolant often requires considerable maintenance and personnel effort, as the tank has a capacity of only around 50 litres. Regular checks are required to ensure a sufficient coolant level and early identification of potential issues. A shortage of coolant can lead to serious problems if the operator continues the cutting process, resulting in excessive wear of the saw blade.
Monitoring is particularly challenging when the power hacksaw is located in an area without IT infrastructure. In such cases, a solution is needed that works independently of existing networks and supports efficient use of maintenance staff.
This is where the io-key comes into play. This innovative system enables continuous monitoring of the coolant level with minimal implementation effort. The current sensor value is transmitted directly to moneo at regular intervals. If deviations occur, notifications are generated immediately, allowing early intervention without the risk of machine downtime. As a result, routine inspection rounds by personnel to monitor the coolant level are completely eliminated.
 Improved machine availability |
 Optimised maintenance scheduling |
 Elimination of routine manual checks |
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On average, customers achieve: |
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€ 1,755 savings in machine costs |
€ 3,600 savings in personnel costs |
100% ROI after 5 months |
Benefits of machine monitoring with the io-key
With the io-key, you can monitor the coolant of your power hacksaw effortlessly and eliminate the need for manual checks by personnel. Your advantages at a glance:
- No infrastructure required: Data is transmitted to the moneo Cloud via mobile communications; no network infrastructure is required.
- Fast ROI: Low acquisition and operating costs enable a rapid return on investment in under a year.
- Accurate replenishment planning: Precise level monitoring enables more efficient use of personnel.
- moneo Cloud instance: The moneo Cloud can be accessed from anywhere.
- Minimal cabling: Only power and sensor cables are required.
Targeted monitoring helps ensure machine availability and prevents unplanned downtime.
Value proposition
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Machine availabilityDemand-based monitoring of a coolant tank
The coolant is stored in a tank on the power hacksaw with a capacity of up to 50 litres. Due to the small size of the tank, the level needs to be checked frequently. The coolant level, in this case the water level, can fluctuate significantly depending on how the saw is used, as losses occur during the sawing process due to carry-over on the material. In addition, water evaporates from the open container, further reducing the level. To prevent an increase in emulsion concentration, the coolant needs to be topped up regularly.
The tank level can be measured using sensors and monitored via the io-key without the need for existing IT infrastructure. This enables demand-based and efficient planning of maintenance activities and personnel. Unnecessary and irregular inspection rounds are eliminated. All machines using coolant are visualised on a clear dashboard, allowing maintenance teams to act proactively and avoid machine downtime.
How is the sensor value transmitted to moneo?
Using the io-key, fast and straightforward set-up is possible, as only two cables need to be connected: the power supply and the connector to the sensor. The sensor values are transmitted to moneo via the mobile network without any additional effort. As a result, no complex IT infrastructure is required to monitor relevant values. In moneo, the data can then be further processed, warning and alarm thresholds can be defined, and notifications can be sent if the level drops below a defined limit, with a defined lead time for the required maintenance.
System structure
coolant level
- Probe (E43203)
- Launching plate (E43380)
- Level sensor (LR7020)
- io-key (AIK001)
How to use the io-key to monitor your coolant
To monitor the coolant level in your tank using the moneo io-key, you first require a moneo Cloud instance. This is set up quickly and easily. The io-key transmits the data directly to the cloud via the mobile network, meaning that no network infrastructure is required. The data can then be displayed on an easy-to-read dashboard.
The LR7020 with a 240 mm probe is used as the level sensor. The probe is cut to the required length – in this case to 19 cm – so that the end is correctly detected in the 20 cm-deep container. This prevents the bottom of the tank from being measured as part of the level. The sensor is then configured using moneo configure.
In addition, warnings and alarms can be defined to notify you when a specified level is reached and the coolant needs to be replenished. Notifications can be sent by email or via Teams, ensuring that alerts are received directly by the responsible colleague and acted upon without delay. This ensures that your machines are always optimally supplied and helps prevent downtime.
