Everything you need to know about predictive maintenance

Predictive maintenance relies on the analysis of real-time operational data combined with advanced artificial intelligence algorithms.

Data collection can be achieved through various methods:

By keeping equipment in optimal working condition, predictive maintenance helps minimize production downtime and achieve significant cost savings by preventing unexpected and costly repairs.

In a geopolitical context where European industry must reinvent itself, efficiency is the key word for all manufacturers.

Adopting a predictive maintenance strategy ensures greater availability of production lines. By preventing potential unexpected production downtime, industries save time, money, and ensure higher production quality.

As Industry 4.0 becomes well-established and artificial intelligence experiences rapid development, predictive maintenance fits perfectly into this process.

Predictive maintenance combines the benefits of Industry 4.0 with data collection and artificial intelligence for processing. This type of solution can help manufacturers stay competitive against their Asian counterparts.

Several methods are available to collect the data needed for predictive analysis.
Traditionally, machine data collection was done through the installation and configuration of specific acquisition modules, using industrial communication protocols such as:

Today, with the development of IIoT, the focus is on the use of non-intrusive, cost-effective data sensors that operate with wireless protocols like LoRa.

For example, our predictive maintenance solution for rotating motors simplifies data collection by using non-intrusive vibration sensors (Wise-2410). Simply install the sensor on the motor, pair it with your gateway (Wise-6610), and configure the data transmission to our prediction software (Wise-IoT/PHM).

With Integral System, the prediction software is included, and the pairing and transmission steps are fully simplified: install the sensor and immediately receive forecasts on the motor's health status.

You can launch your predictive maintenance system using only vibration data from a motor. This efficient approach allows you to enter the IoT world in a simple and cost-effective way.

Once your setup is in place, you can expand your system by adding various sensors to enrich the list of collected data and generate key performance indicators (KPIs) relevant to your operations.

With vibration data, you immediately obtain two essential KPIs:

These indicators allow you to significantly optimize your maintenance strategy.

By adding additional sensors to measure energy consumption, temperature, humidity, and other parameters, you can access new KPIs such as:

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For critical or costly motors and equipment, collecting this data helps protect your investments and improve overall profitability.

Overall, you have two options for storing and hosting your IIoT data:

The choice between these two options depends on several factors, including the size of your business, the volume of data to be processed, regulatory constraints, and your security priorities.

In summary, cloud offers flexibility and easy access to data, while local hosting ensures greater control and enhanced security. The choice of hosting strategy will depend on your priorities regarding security, costs, and operational needs.

LoRa technology is a radio signal that enables wireless data transmission and reception. LoRaWAN is the communication protocol that defines how this data is transmitted through the network.

To use the LoRaWAN protocol, you have two options:

Implementing a predictive maintenance strategy involves investments across three main categories:

At Integral System, we offer turnkey solutions that include all of these components: hardware, software, pre-configuration, and technical documentation to facilitate installation. We also offer a Proof of Concept launch package, which allows for a quick installation and testing of our predictive maintenance technology on a limited number of machines, at attractive rates. This approach allows businesses to experience the benefits of our solution before committing to larger deployments.