Abnormal temperature rise is one of the earliest and most reliable signs of failure in industrial assets. For this reason, temperature monitoring has become an essential practice within predictive maintenance strategies, enabling the identification of overloads, friction issues, electrical faults, and component degradation before these events lead to unplanned downtime.
By continuously or periodically tracking thermal data through industrial sensors, thermographic cameras, or portable devices, maintenance teams can make evidence-based decisions, extending asset lifespan and increasing operational reliability.
In this article, we explore the concepts, technologies, and applications of thermal asset monitoring, and how Dynamox integrates this approach into its predictive maintenance solutions.
What is temperature monitoring in industry?
Temperature monitoring in industry refers to the systematic measurement of thermal variations in operational assets, aiming to identify anomalies before they evolve into critical failures.
This technique is widely used in predictive maintenance, as temperature is one of the first indicators of changes in the operating conditions of electromechanical components. When properly applied, this strategy allows for early detection of overloads, excessive friction, insulation failures, or ventilation issues.
There are two main application methods: spot measurement and continuous monitoring. Spot measurement is performed manually and periodically using instruments such as industrial thermometers, infrared pyrometers, or portable sensors. It is suitable for low-criticality assets or structured inspection routes where field data collection is feasible and safe.
On the other hand, continuous monitoring involves fixed sensors connected to digital platforms, capable of recording and transmitting data in real time. This approach offers broader coverage and greater sensitivity in detecting abnormal thermal variations, enabling faster and more accurate responses from the maintenance team.
More than just flagging out-of-range values, thermal monitoring reveals symptoms of progressive degradation. Temperature rise is often not the direct cause of failure but an indication that the asset is operating outside optimal conditions. When this occurs persistently, component wear accelerates, shortening their service life.
Therefore, temperature tracking should be interpreted alongside the asset’s historical behavior and other condition variables, establishing itself as a key tool for anticipating failures and preserving operational reliability.
Why monitor the temperature of industrial assets?
Monitoring the temperature of industrial assets is essential to ensure reliability, efficiency, and operational safety. Thermal elevation beyond specified limits can trigger a range of undesirable effects, such as: Accelerated mechanical wear; material degradation; performance loss; in extreme cases, catastrophic failures or fire hazards.
Even minor but recurring temperature variations indicate that the asset is operating outside ideal conditions, compromising its integrity over time. Common failures associated with temperature rise include:
- Electrical overload: causes increased current and heating in electric motor windings.
- Excessive friction: due to poor lubrication or wear in bearings and gears.
- Thermal or electrical insulation issues: compromising the operational stability of motors and transformers.
- Inadequate ventilation: failures in cooling systems or obstructions preventing heat dissipation during operation.
- Loose or oxidized connections in electrical panels: leading to localized heating and risk of electrical arcing.
In addition to indicating thermal faults in assets, temperature variation can be combined with other operational parameters to enhance diagnostic capabilities. When correlated with data such as vibration, electric current, or pressure, it becomes possible to identify complex degradation patterns.
Thus, thermal monitoring evolves from a simple spot measurement to a strategic tool in predictive asset management, allowing failures to be anticipated with greater precision and interventions to be planned and executed effectively.
Methods and technologies for thermal monitoring
Temperature monitoring can be performed using various methods, each with its own characteristics, applications, and levels of automation. The choice of the appropriate technology depends on factors such as asset type, criticality, data collection frequency, and access conditions. Below is a comparison of the main technologies used in the industry:
In summary, the table highlights how each method supports different strategies and operational needs, from visual spot inspections to automated, continuous monitoring of critical assets.
When to apply each method?
Here’s how to adapt each technology to the context of specific equipment:
- Thermometers and pyrometers: recommended for low-criticality, easily accessible assets where spot measurements are sufficient and operational risk is low.
- Thermographic cameras: ideal for visual inspections of large areas, such as electrical panels, transformers, and multiple connections.
- Wireless portable sensors: used in predictive routes with periodic data collection, offering safety, standardization, and convenience for distributed measurements across the plant.
- Fixed sensors with continuous monitoring: suitable for high-criticality assets, 24/7 operations, or environments with a high risk of thermal failures. They also provide real-time insights into asset health and automatic alerts for agile decision-making.
Each technology has an ideal application context. The most effective strategy often involves combining these methods, aligned with criteria such as criticality, frequency, accessibility, and risk.
Advantages of continuous monitoring
If your industrial plant operates with high-criticality assets, continuous monitoring offers significant operational advantages over other technologies:
- Instant detection of incipient thermal faults, even outside business hours or during abrupt load variations.
- Reduced reliance on manual inspections, enhancing team safety and data reliability.
- Detailed historical records and thermal trend analysis, essential for identifying degradation patterns and anticipating failures.
- Integration with other operational data, such as vibration and current, enabling more accurate cross-diagnostics.
Remote monitoring is carried out through sensors connected to gateways and digital platforms, allowing data access regardless of the asset’s location.
One example is Dynaloggers, Dynamox’s wireless sensors for continuous asset monitoring. These devices transmit collected data via an IoT gateway, the DynaGateway, which uploads the information to the Dynamox Platform for visualization.
By adopting fixed sensors with remote connectivity, predictive maintenance shifts from a reactive approach to an analytical regime, with decisions based on historical data, thermal profiles, and configurable operational thresholds. .
What are the most common applications of temperature monitoring?
Thermal monitoring is widely applicable in industrial environments where heat may indicate faults or performance degradation. Certain assets and systems are particularly sensitive to thermal variations, making temperature tracking essential to prevent unplanned downtime and optimize component lifespan.
Here are the most frequent use cases:
Electric motors
Temperature variation in motors may indicate overload, winding faults, ventilation issues, or dirt accumulation. Monitoring heat helps prevent coil burnout and ensures operation within nominal ranges.
Gearboxes and bearings
Friction caused by wear, misalignment, or insufficient lubrication leads to temperature rise. Continuous measurement enables early detection of mechanical faults in these torque transmission-critical components.
Centrifugal and piston pumps
In pumps, thermal variations signal cavitation, blockage, misalignment, or mechanical seal failure. Additionally, combining temperature and vibration data provides a more comprehensive diagnosis.
Electrical panels and connections
Temperature rise in terminals, circuit breakers, or busbars indicates poor contact, overload, or phase imbalance. Early detection through temperature monitoring helps prevent fire hazards and equipment loss.
Transformers and frequency inverters
These components naturally generate heat, but excess temperature points to insulation failure, overload, or cooling system defects. In such cases, thermal monitoring is essential for ensuring stability and safety.
Industrial environments with high thermal load
Facilities with furnaces, ovens, boilers, or continuous heating processes require strict thermal control to ensure safety, efficiency, and regulatory compliance.
Proper use of fixed industrial temperature sensors allows these assets to operate within designed limits, reducing premature wear and preventing failures that could impact production.
If you work with temperature monitoring, especially in industrial environments, don’t miss the DynaTalks episode “Electrical busbars: Paths to prevent overheating.” (This content is presented in Portuguese, please make use of the automatic subtitles generator in your browser in your preferred language).
In this episode, Marcelo Martins, Danilo Braga, and Vinicius Saraiva explore the specific challenges of thermal monitoring in busbars, discussing critical components, causes of heat-related failures, and how the right tools can prevent unexpected downtime. A technical and straight-to-the-point discussion.
How to interpret temperature data?
Correctly interpreting temperature data is essential to turning thermal measurements into effective predictive actions. More than simply observing high values, it’s necessary to understand the asset’s context, identify variation patterns, define appropriate operational thresholds, and correlate temperature with other condition variables.
Below, we detail the three pillars of this technical interpretation:
Absolute temperature vs. Abrupt variations
Absolute temperature refers to the exact value recorded at a given moment. It should be compared to the limits established by the manufacturer or defined based on the asset’s historical behavior. For example, medium-voltage electric motors typically operate within a range of 60 °C to 85 °C. Exceeding this range increases the risk of insulation degradation, efficiency loss, and electrical failure. .
However, not all problems manifest through high values. Many failures begin with abrupt variations occurring over short periods. For instance, a gearbox that jumps from 65 °C to 78 °C in less than an hour — without changes in load or environment — may be experiencing abnormal friction due to lack of lubrication, misalignment, or internal wear.
These fluctuations, even within the “acceptable” range, indicate changes in thermal behavior and should be treated as warning signs. That’s why monitoring thermal trends over time is just as important as tracking absolute values.
Alert thresholds and trend analysis
Setting alert thresholds is a recommended practice for continuous monitoring. Typically, a pre-alarm threshold is defined when the temperature approaches 80% of the critical value, and an alarm threshold is set for immediate intervention. These values vary depending on the asset, operating regime, and environment.
Trend analysis allows teams to observe how temperature behaves over days, weeks, or operational cycles. This makes it possible to predict when an asset will reach a critical level and schedule interventions in advance, minimizing production impact.
Analytical platforms — such as Dynamox Platform — enable automated visualization of these curves, optimizing the decision-making process for maintenance teams.
Correlation with other variables: vibration and current
Temperature alone is already a valuable indicator of developing faults. However, its diagnostic power becomes even stronger when analyzed alongside other monitored variables, such as vibration and electrical current. This multivariable correlation enables more accurate diagnostics and earlier detection of complex failures.
For example, a simultaneous increase in temperature and vibration in a pump may indicate cavitation, misalignment, or mechanical looseness in rotating components. Meanwhile, a combination of thermal rise and increased current may suggest electrical overload, winding faults, or phase imbalance — conditions that, in isolation, might go unnoticed or appear inconclusive.
This integrated analysis, made possible by sensors that collect thermal, vibrational, and electrical data in sync, enhances the maintenance team’s ability to detect incipient failures earlier. As a result, it leads to reduced Mean Time to Repair (MTTR), increased Mean Time Between Failures (MTBF), and greater efficiency in predictive decision-making.
What are the benefits of temperature monitoring?
Temperature monitoring is one of the most effective practices for strengthening predictive maintenance, increasing asset reliability, and reducing operational costs. Below, we detail the key advantages this strategy brings to industrial operations:
Early fault detection
Temperature is one of the first parameters to show variations when mechanical or electrical anomalies occur. By continuously monitoring this indicator, it’s possible to identify incipient failures such as excessive friction, ventilation issues, overloads, or insulation degradation before they escalate into breakdowns.
In other words, temperature monitoring extends the maintenance team’s response window and enables planned interventions, minimizing production impact.
Increased MTBF and asset availability
Mean Time Between Failures (MTBF) is directly influenced by the ability to anticipate issues. With thermal monitoring, assets operate longer under optimal conditions, reducing the number of unexpected shutdowns. As a result, operational availability increases, process efficiency improves, and lifecycle cost per asset decreases.
Reduction of emergency interventions
Emergency corrective actions are typically more costly, risky, and time-consuming. By implementing a temperature monitoring strategy, it’s possible to shift from reactive maintenance to a predictive approach, significantly reducing the number of urgent interventions. This also frees up the maintenance team to act more strategically and proactively.
Optimization of maintenance plans
Reliable and historically organized temperature data allows maintenance plans to be revised based on actual asset behavior, rather than fixed intervals or manufacturer guidelines. This enables extending intervals where thermal stability is observed or anticipating inspections when temperature trends rise — making the plan more efficient and aligned with the plant’s operational reality.
Improved operational safety
Assets operating above temperature limits pose risks to equipment integrity, the environment, and personnel. In electrical panels, for example, hot spots may indicate loose connections with potential to cause electrical arcs or fires. Continuous monitoring enables the identification of hazardous conditions before they become critical, reinforcing safety culture and preventing industrial accidents.
Frequently asked questions about temperature monitoring – FAQ
What is the ideal operating temperature for industrial motors?
The ideal temperature varies depending on the motor type and its insulation class. Generally, industrial motors operate safely between 60 °C and 85 °C on the housing. However, for motors with insulation class B, for example, the maximum limit can reach 130 °C in the windings, considering ambient temperature, thermal rise, and safety margin. Therefore, it’s essential to follow manufacturer recommendations and consider the operating environment when setting alert thresholds.
How can I tell if an asset is overheating?
Overheating can be identified through continuous temperature monitoring and trend analysis. Abrupt variations, even within seemingly safe ranges, are also signs of anomalies. Sensors configured with pre-alarm and alarm thresholds help detect these conditions in advance.
Do portable sensors work for all assets?
Portable sensors are highly versatile and suitable for most assets monitored in predictive routes. However, for equipment with limited access, continuous operation, or high thermal failure risk, fixed sensors with automated data collection are recommended. The choice depends on asset criticality and the plant’s maintenance strategy.
What’s the difference between sensor-based monitoring and thermography?
Thermography provides a thermal image of a wide area and is useful for visual spot inspections, such as in electrical panels or multiple connections. In contrast, sensors measure the temperature of a specific point digitally and objectively, and can be used continuously (fixed) or in inspection routes (portable). For permanent monitoring and historical data generation, sensors are more suitable.
When should continuous monitoring be adopted?
Continuous monitoring is recommended for critical assets, hard-to-access equipment, or systems subject to rapid thermal variations. It’s also essential in 24/7 operations or where immediate response is required. This approach offers greater precision in fault detection and enables proactive actions based on historical data and automated alerts.
How Dynamox enhances temperature monitoring
Temperature monitoring has evolved from a simple spot measurement to a key practice within predictive maintenance strategies. When performed continuously and in an integrated manner, it enables the detection of incipient failures, optimization of interventions, reduction of operational risks, and preservation of industrial asset integrity.
In a scenario where reliability and availability are increasingly critical indicators, tracking the thermal evolution of equipment is not just a best practice—it’s a strategic necessity.
In this context, Dynamox offers a complete ecosystem to enhance this journey. Wireless sensors (DynaLogger) perform continuous temperature and vibration monitoring, providing data on asset behavior. The DynaPortable enables thermal data collection during inspection routes, being portable and ideal for plants with hybrid strategies.
All data is integrated into the Dynamox Platform, which centralizes information, generates configurable alerts, and enables precise trend tracking through analytical tools.
Beyond technology, Dynamox provides specialized technical support for asset data analysis and guidance in building customized predictive plans. This allows companies across various industrial sectors to evolve from reactive monitoring to data-driven maintenance, boosting their reliability, safety, and performance indicators.
To learn how to apply this strategy in your plant, speak with a Dynamox specialist!