Smart Maintenance
Smart Maintenance
PdM is a notable area to help an organisation realise the value of its investments. According
to industry estimates, manufacturing organisations without a PdM plan suffers 800-1000
hours of Downtime annually. Adopting PdM techniques may reduce unplanned Downtime
by 60 percent and financial impact by 36 percent.
Maintenance strategies can be any of three categories, as shown in figure 1: Reactive Maintenance, Preventive
Maintenance, and Predictive Maintenance.
Maintenance Strategies
Seasonal Data
Maintenance Records
Vibration levels, temperature,
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Predictive maintenance assumes that, if input variables are known, it is possible to predict the failure
of a machine component in the future. The part can be replaced with a new one just before it fails.
PdM started as a visual inspection method and evolved into automated procedures. These automated
procedures use advanced signal processing techniques based on ML, fuzzy logic, neural networks,
and others. If paired with integrated sensors, predictive maintenance allows you to reduce machine
downtime and maximise component lifetime with a positive impact on productivity, spare parts
inventory management, and maintenance costs. The process of PdM includes prognosis and diagnosis
activities. Prognosis predicts the faults due to natural wear, and diagnosis examines the variation
between expected and observed parameters so that you can evaluate working conditions if particular
failures happen.
1. Accounts for actual conditions and applications: The Maintenance of any equipment depends upon
its condition and performance in its actual working environment and real-world applications. A generic
schedule from statistical averages may not be suitable for your facility. For example, a manufacturer may
instruct the replacement of a particular pneumatic system every 1,000 hours. However, this instruction is
not applicable if the system suffers from dust exposure and other environmental degradation. Integrating
the pressure data into a PdM enables you to accurately determine when the filters will be sufficiently
clogged to change them before the total system fails.
2. Early fault detection: A key benefit of predictive maintenance is detecting an impending failure that
may pause your production schedule. For example, a PdM plan involving regular temperature profile
assessments of your equipment may reveal an abnormal rise in the operating temperature in recent
months. This overheating problem, if not solved, may lead to quicker degradation of the wiring. The early
alert will enable you to switch out the problem part to avoid a catastrophic failure. This alert also results
in reduced Downtime.
3. Less downtime and improved reliability: PdM reduces Downtime as Maintenance happens only when
required. Predictive maintenance and its supporting tools are at the heart of reliability. The combination
of monitored equipment and helpful information filtered from data will help you recognise maintenance
needs when they arise.
4. Better performance and reduced cost: It is vital to perform essential maintenance tasks on time.
Timely maintenance ensures that the production line equipment will continuously operate at peak
performance. PdM involves maintaining equipment when needed, not after the escalation of a
problem. This maintenance has positive implications for costs, such as reduced downtime and power
requirements.
5. Extends equipment life: PdM increases your equipment’s useful life. It also increases the reliability of
the machines, making it possible for you to wait much longer for needed refurbishment or replacement.
Attending to problems at their nascent stage extends the motor’s life span. A motor with ten years of
functional life expectancy can see its life span extended by monitoring its condition.
Condition Monitoring: You can use condition monitoring to analyse maintenance requirements. Downtime,
unnecessary practices, and asset failures can be avoided. The breach of certain thresholds initiates
maintenance in condition monitoring. The process may commence if there are indications of impending
failure. Industries practice these main condition monitoring methods:
i. Temperature and thermography: Cameras are integral to the thermography process. For equipment
appraisal, the camera captures infrared radiation. Assets emit this infrared radiation. A temperature
variation identifies a potential problem and initiates maintenance. Thermographic analysis detects
disconnections, wear, rusting, and delamination invisible to the naked eye. This technique finds use in
electrical connections and systems, discharge patterns, roof maintenance, fluid analysis, and discharge
patterns.
ii. Vibration analysis: Sensors, in vibration analysis, detect vibrations caused by degraded asset
components. Vibrational changes produced by the equipment are subject to broadband vibration
analysis and shock pulse analysis techniques. These methods help to find the flaws present in the
parts. Vibration analysis tests component alignment and detects imbalances, clearances, resonances,
and gear failures for rotating equipment and machines, such as compressors, water pumps, and
engines.
iii. Motor circuit analysis: The electric signature analysis technique in the motor circuit analysis
method determines the motor’s overall health. Motor circuit analysers easily find faults in electric
motors and their components. This analysis works on both AC and DC motors, and you can use
it in online mode (when the motor is running) or in offline mode (the time when the motor is de-
energised). Motor circuit analysis can ascertain issues related to incoming power, analyse motor
electrical circuitry, analysis of mechanical motor components, gears, and motor mechanical
couplings.
iv. Ultrasonic Analysis: In ultrasonic analysis, ultrasound detects high-frequency (30-40 kHz)
sounds and analyses them by changing them into audio and digital data. Technicians perform an
in-depth vibration analysis of the defective equipment to locate the cause of the issues. You can
use ultrasonic analysis to detect leaks, and cracks, inspect electricals, test valves, and optimise
lubrication practices.
v. Laser-shaft alignment: Bad equipment installation practices cause mechanical failures. Misaligned
shafts result in bearings failures. Laser-shaft alignment examines shaft alignment to verify correct
installation and thus prevent future performance issues. The technique identifies defects in the
surface and subsurface of several materials.
vi. Oil analysis: You can use this method to analyse a lubricant oil’s condition. Your factory equipment
may deteriorate due to wear particles, viscosity contamination, and water contamination in
lubricants, thus inducing failure of function. Typical oil analysis applications include compressors and
gearboxes.
A simple local IoT PdM comprises sensors (gather information) and gateways (process data and transmit it
comprehensively to monitoring devices). The information is analysed, and the maintenance staff manually
fixes all issues.
Local monitoring
equipment
Sensors are simple data-gathering devices. They have limited functionality. Compared to sensors, gateways are
comparatively sophisticated. Sensors make possible particular remote tuning and reverse connectivity options.
PdM offers many options for data analysis and remote control. Cloud migration allows you to link your
on-premises devices to a web platform having a specialised web application.
• Data aggregation: The gateways process vast quantities of raw information sent from the sensors. This
information subsequently moves to cloud storage. The storage connects big data warehouses with ML
algorithms. The algorithms continuously improve and update the application.
• Illustration of trends: Faults in equipment have ties to on-site production processes. Failures are usually
the culmination of a long chain of interconnected factors. You can use the IoT PM application to create
tables and charts illustrating statistics sourced from sensors automatically. These arranged data highlight
trends in malfunctions, revealing the actual nature of problems on-site.
• Report creation: The data gathered from gateways can be processed, analysed, and organised into
reports. These reports must be readable for a faster operator response.
• Alerts: Before being sent to the application user, all potential harmful tendencies and dangerous signals
must be discovered and highlighted clearly.
Management of alarms
and indicators
Remote control
Testing connection quality
through the system
Report management
Companies running an IoT predictive maintenance application are mostly large multi-location enterprises. It
is thus essential to have local IoT network management and factory management in place.
Equipment management
Since equipment maintenance is the core task of the IoT PdM system, the user must have granular control
over equipment functions.
The analysis and monitoring of local IoT network data is vital for mapping the current condition of a business.
Local network monitoring can help discover failure trends and factory-level problems.
The user must receive vital and urgent messages as soon as the IoT PM Web application analyses information
and identifies the trends.
Report management
Reports are readable and allow you to obtain a usable picture of a company’s equipment situation. An IoT
web application generally features standard overview reports (based on hard-coded rules) and advanced
reports that cover historical data analysis. Cross-comparing various trends and data channels obtain
additional industry-relevant insights.
Remote control
Inadequate equipment capabilities strongly restrict the actual scope of remotely controlling the IoT PdM system.
Most sensors are primitive devices that can only communicate with gateways in a one-way fashion. Furthermore,
the specifics of gateway architecture forbid the creation of software that can change sensor settings.
IoT PdM remote control options are usually limited to checking connection quality and gateway management.
Remote application control uncorks multiple features, including gateway firmware up-gradation, changing
gateway settings, and testing hardware sustainability. You can use the IoT system to improve connection
quality and solve potential connectivity issues.
PdM uses a data streaming mechanism from machine instrument devices (pressure, temperature, etc.) to
determine the up-normal condition in machine behaviour and then predict the possibility of defectiveness
during a particular timeframe. You can do ML modelling according to the following phases:
Data Collection
In the first phase, smart sensors collect data from possible failing parts inside the operating machine. You can
achieve better results if you use a data set in the overall process. The data set demonstrates the machine’s
condition and behaviour during its lifecycle and captures the potential failures. Scientists can use data to
develop PdM models.
Data Analysis
Combining the data streaming process with machine processing settings (such as set points, configuration,
and historical data) achieves higher data prediction accuracy and better representation. These details
collude from different sources, e.g., the enterprise management system.
Data Modeling
A comprehensive analysis of data streaming reveals the dependencies. Data modelling performs technical
propositions related to possible failure indications and creates specific behaviours for the anticipated failure.
Data Prediction
Data modelling primarily detects failures and builds ML algorithms as the foundation for predictive models.
The various steps in data prediction evaluate failure detection accuracy before the prediction models are
finally approved.
The K6CM is the latest motor condition monitoring device that can quantify the
status of three-phase induction motors. It has in-built EtherNet/IP & Modbus TCP
communication to remotely monitor motor current, vibration & temperature, or
insulation resistance depending on the model selected
Part number: K6CM-CICB200
ZX series smart Sensors are Laser sensors with a built-in Amplifier. It has a
CMOS Laser Sensor with a resolution of 0.002 mm, which is suitable for simple
measurements.
Part number: ZX-TDA41 2M
Vibration sensor made with proprietary Piezo Ceramic Material with built-in Amplifier.
Part number: VS-BV203-B
The Honeywell SMART Arc Position Sensor is one of the most durable, adaptable,
lightweight, and non-contact position sensors, enabling absolute position sensing
with enhanced accuracy. SMART Position Sensors provide a self-diagnostics feature
and data gathering for enhanced reliability and closed-loop feedback control.
This simple, robust, arc position sensor offers an IP69K sealed package, eliminating
mechanical failure mechanisms, reducing wear and tear, improving reliability and
durability, and minimising Downtime.
Part number: SPS-A100D-HAMS
The Sentrius™ IG60 brings all of Laird Connectivity's industrial wireless and IoT
capabilities into one unique solution. Based on Laird Connectivity's 60-series and
BL654, capture data from legacy serial (RS-232, 422, 485) industrial devices or
Bluetooth 5 sensors, add edge intelligence and send to the cloud with 802.11ac Wi-Fi
and global LTE Cat 1 (3G/2G fallback) wireless connectivity.
Part number: 455-00113
The Fluke Ti450 provides the most advanced image quality in this camera
series, offering the versatility and features needed for a thorough inspection,
troubleshooting, and maintenance.
Part number: FLK-TIS60+ 9HZ
The KTP400 Basic are touch panel with additional buttons for simple applications. It
has high-resolution dimmable widescreen displays with 64,000 colours and a touch
and button function. It can be interfaced with various PLCs.
Part number: 6AV2123-2DB03-0AX0 | 6AV2123-2GB03-0AX0 |
6AV6 647-0AH11-3AX0 | CM-BF537E | 6AV2124-1QC02-0AX1
Magelis SCU small touchscreen operator interface controller (HMI) is supplied with
24V DC, has a 3.5" colour TFT LCD display and 128MB EPROM. It also has 16 digital
inputs, 10 digital outputs, 1 host + 1 mini-B USB port, 1 RS232C / RS485 port and 1
CANopen port.
Part number: HMISCU6A5
Pluto is a cost-effective, powerful, compact safety PLC for all machine safety
applications. Totally 46 I/O: 24 failsafe inputs + 16 non-failsafe outputs/failsafe inputs
+ 4 individually failsafe relay outputs + 2 individually failsafe transistor outputs.
Part number: 2TLA020070R1700
Altivar 320 variable speed drive can feed single-phase synchronous and
asynchronous motors. Its compact form factor allows vertical stacking of drives
inside machine frames. It works at a rated power of up to 1.5kW / 2hp and a rated
voltage from 200V to 240V AC. Its robust design with IEC 60721-3-3 class 3C3 coated
printed circuit boards allows to extend machine availability in harsh environmental
conditions, for example, at ambient temperatures of up to 60°C, without the need
for additional cooling.
Part number: ATV320U15M2C
ABBs SACE Preventive Maintenance for Emax and New Emax low voltage circuit-
breakers.
Part number: 1SDA059763R1
Zelio Logic SR2/SR3 range has a Bluetooth interface which is suitable for use in
industry and building/service sector. It supports a 10m operating distance. It weighs
around 0.015kg.
Part number: SR2BTC01 | SR3MBU01BD | SR2SFT01
The DXMR90 Series Controller is an industrial controller within the Banner DXM family
of controllers that consolidates, processes, and distributes data using industrial or
web services protocols.
Part number: DXMR90-X1
The die-cast aluminium enclosure IP-Pro Alu EMC from nVent SCHROFF
offers robust IP protection up to IP67, is EMC shielded and is shock, vibration
and weather resistant. It can be configured for electronics with standardised
or customer-specific form factors. The enclosure can be complemented by
the expertise of nVent SCHROFF, which includes innovative solutions for PCB
fixing, cable management and optimized cooling concepts.
Part number: 26880002 | 26880005 | 26880014
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