OMRON Launches K7GE-MG Insulation Resistance Monitoring Device that Automates the Measurement know-how of Skilled Maintenance People -Remote Condition Monitoring Contribute Preventing Sudden Machine Failures-

  • November 30, 2020

OMRON Corporation (HQ: Shimogyo-ku, Kyoto; President and CEO: Yoshihito Yamada) will release the K7GE-MG insulation resistance monitoring device, which automatically measures the insulation resistance of equipment, in Japan on December 1, 2020, as a new series of condition monitoring devices that monitor abnormal conditions at manufacturing sites on behalf of human check by tester. The K7GE-MG will be launched on a global basis at 2021. The K7GE-MG contributes to reduce equipment checkup human-hour and prevent unexpected equipment breakdowns by monitoring the deterioration of insulation resistance with numerical value for critical parts.

c1130.png[Insulation resistance monitoring device K7GE-MG]

In recent years, aging equipment and shortage of skilled maintenance people have caused sudden breakdowns and stoppages at manufacturing sites, significantly affecting overall factory productivity.
This challenge is further compounded by restrictions on movement at overseas production sites due to the COVID-19.
Since December 2017, OMRON has been providing Condition Monitoring Device that combines our strengths in sensing technology and anomaly detection algorithms to monitor abnormal conditions of equipment in order to eliminate the loss of production line stoppages at manufacturing sites.
We have contributed to maintenance innovations that can be completed on the production site by developing equipment that can monitor motor condition & control panel temperature abnormalities and that can be easily installed on existing production line on site.

The new K7GE-MG enables the detection of insulation failure in equipment such as servo motors.
Accurate measurement of insulation resistance used to require maintenance expert knowledge of measurement methods and the stoppage of production facilities is necessary for measurement, which resulted in production line sudden stop between periodic inspections due to insulation failure.
The K7GE-MG now incorporates the inspection know-how of skilled maintenance people into its functions, enabling highly reproducible measurements to be carried out automatically.
Compared to conventional manual measurements by mega ohm meter, the K7GE-MG reduces the measurement man-hours and monitor the slightest abnormality sign of machine.
In addition, the K7GE-MG has a communication function to monitor the degradation trend of insulation resistance remotely from the office or other locations without visiting the manufacturing site, thereby reducing the maintenance man-hours and contributing to the prevention of sudden production line.

OMRON set forth a strategic concept called "innovative-Automation" consisting of three innovations or "i's"--"integrated" (control evolution), "intelligent" (development of intelligence by ICT), and "interactive" (new harmonization between people and machines). By continuing to expand the line-up of Condition Monitoring Device, we will continue to work with our customers to accelerate the development of "intelligent" manufacturing sites, which is the key to realizing "innovative-Automation", and dramatically improve productivity and quality at manufacturing sites.

Main features of the K7GE-MG series

  1. Highly reproducible measurements, incorporating the measurement know-how of skilled maintenance people.
    The measured value of insulation resistance varies greatly depending on the operating and wiring conditions of the machine. As a result, conventional manual measurement by mega ohm meter is prone to variations due to the operator and measurement conditions, making it difficult to perform measurements with high repeatability. The K7GE-MG incorporates the know-how of the waiting time for measurement by skilled maintenance people into its functions, enabling highly reproducible measurements necessary for trend monitoring and contributing to the realization of planned maintenance.
  2. Low voltage measurement with no overload on the machine equipment
    The K7GE-MG has a fixed applied voltage of 50VDC, which is much lower than the applied voltage of 500VDC/1000VDC of the mega ohm meter used for manual measurement, and therefore does not place an overload on the machine equipment. Insulation registance value by measurement at 50VDC is almost the same results that measured with a mega ohm meter.
  3. Data can be obtained from remote locations by connecting to a network.
    The K7GE-MG can provide remote monitoring environment by a network connection using HMI, PLC and/or serial gateway equipment for communication between manufacturing site and office. In addition, you can check the measurement results at the site by the LCD display in the K7GE-MG with high visibility.
  4. High usability according to equipment and application
    You can built up to eight probe units for one K7GE master unit to the target measurement equipments of the same system. The number of probe unit can be installed according to measurement equipment situation, hence space efficiency can be achieved without uselessness.
    c1130e_3.png In addition, The K7GE-MG enables periodic inspections with a mega ohm meter while it is installed. [Patent Pending*3]
    The K7GE-MG internal contact isolate between the target measurement equipment and the K7GE-MG internal circuit except during measurement, hence it does not affect the measurement results of the mega ohm meter. Even if you need to measure with a calibrated measuring instrument, you can handle it easily.

*1 Insulation resistance: Insulation resistance refers to the resistance value between electrical circuits (between electrical circuits and between electrical circuits and ground) where insulation is ensured in electrical circuits through which current flows.
*2 Insulation failure: Insulation failure is a condition in which electrical leakage occurs due to deterioration of the insulation between the enclosure and the electrical circuit to prevent electrical leakage. As the insulation failure occurs, risks such as electric shock, fire and failure occur, which greatly affects the safety and productivity of the equipment.
*3 "Patent pending" indicates patent pending in Japan. (As of December 2020)

About "innovative-Automation"
Recently, OMRON has developed a manufacturing innovation concept, called "innovative-Automation" With this concept, OMRON is currently committed to bringing innovation to manufacturing sites through three key innovations, or three "i's." Through these innovations in the area of automation, OMRON aims to enable significant productivity improvements in manufacturing sites in order to achieve high-value-added manufacturing. With the first "i," "integrated" (control evolution), OMRON will seek to advance automated control technology so that virtually any operator, even inexperienced operators, can effortlessly perform work that previously required the expert skills of experienced workers. With the second "i," "intelligent" (development of intelligence by ICT), OMRON seeks to create constantly evolving equipment and production lines. By adopting a wide range of control devices and artificial intelligence (AI), machines can learn through experience and maintain themselves in optimal condition. For the third "i," "interactive" (new harmonization between people and machines), OMRON pursues the development of a new harmonious relationship between human operators and machines; as they work together in the same workspace, machines will be able to assist human operators by recognizing human thoughts and behavior in a way that only OMRON, a specialist control equipment manufacturer who knows production floors inside and out, can realize.

About OMRON Corporation
OMRON Corporation is a global leader in the field of automation based on its core technology of "Sensing & Control + Think". OMRON's business fields cover a broad spectrum, ranging from industrial automation and electronic components to social systems, healthcare, and environmental solutions. Established in 1933, OMRON has about 30,000 employees worldwide, working to provide products and services in around 120 countries and regions. For more information, visit OMRON's website:

Contact (media):
Brand Communications Department
OMRON Corporation
TEL: +81-75-344-7175
Contact (product information):
Component Division, Product Business Division HQ,
Industrial Automation Company,
OMRON Corporation
TEL: +81-75-344-7231

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