Predictive Maintenance with IoT & AI
Preventing unplanned production shutdowns by analyzing vibration and temperature data directly on the edge.
OVERVIEW
High-Performance Edge Integration
Failure of critical rotating equipment like motors, compressors, and pumps in industrial plants leads to massive losses. Our predictive maintenance solutions analyze high-frequency vibration and temperature data using rugged edge computers. Controlsan engineers model wear trends using machine learning algorithms to warn maintenance crews before failures occur, maximizing uptime.
Our solutions guarantee zero system loss and continuous protection across critical assets.
Detailed Solution Analysis
1. Fundamentals of Vibration and Temperature Analysis
Mechanical wear in rotating machines first manifests as high-frequency vibration deviations, followed by excessive temperature increases. High-precision accelerometers and temperature sensors placed in the field continuously collect data from shaft bearings. The raw signal data is converted from the time domain to the frequency domain using FFT. This enables diagnostics of specific fault types by inspecting shifts in signature frequencies (1X, 2X, 3X rotation frequencies).
2. Ruggedized Edge AI Hardware
Vibration analysis gathers thousands of data samples per second per sensor. Uploading this massive volume of data to the cloud incurs high network costs, latency, and security risks. Controlsan deploys fanless, industrial-grade Box PCs from AAEON and ICC in field cabinets to process data directly adjacent to the sensors. Optimized machine learning models running on edge computers analyze data in real time.
3. Early Detection and Fault Pattern Library
Our predictive maintenance library maps common industrial faults like bearing wear, coupling unbalance, shaft misalignment, loose parts, gear damage, and electrical stator/rotor issues. The system isolates the location and severity of the defect 2 to 4 weeks before any audible noise or thermal spike occurs, allowing managers to plan repair windows rather than reacting to catastrophic failures.
TECHNICAL CAPABILITIES
System Features & Engineering Architecture
01
High-Speed Sampling
Captures micro deviations by collecting thousands of data points per second from vibration sensors.
02
Local Edge AI Inference
Processes data instantly on edge computers in the factory without transferring it to the cloud.
03
Failure Pattern Library
Classifies defects such as bearing wear, unbalance, and shaft misalignment in advance.
04
Smart Alert Triggering
Sends automatic work orders and notifications to maintenance managers upon anomaly detection.
Engineering & Integration Power
Kontrolsan is not just a hardware supplier. We analyze your field on-site, draw up exact network topology and sensor layout diagrams, install secure cabinets, run cables, configure Zero-Trust networks, and integrate all field data securely with your central SCADA and komuta kontrol (PSIM) systems.
OPERATIONAL VALUE
What are the Key Benefits?
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Get in touch with our expert engineering team for site surveys, detailed topology design, and custom hardware suggestions.
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