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Indeema’s Case study on IoT Solution for Machinery Condition Monitoring

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Short Overview

The iReDS is a component of the ViDiSy product (Vibration Diagnostics Systems), which is an end-to-end industrial Internet of Things (IoT) solution designed specifically for the complex monitoring and analysis of rotating mechanisms in manufacturing. This innovative system revolutionizes the way machinery is monitored and maintained, enabling remote monitoring to prevent downtime and efficiently identify the cause and location of faults. This reduces the number of unplanned downtimes caused by key element failures by up to 75%.

Project Details

  • Industry: Digital Manufacturing
  • Team: 12 engineers
  • Lifetime: 2017-2019
  • Services: R&D, Firmware Development, IoT Development, MVP, UI/UX, Desktop Development, Web Development, Cloud Services, Software Testing Services, Tech Advisory
  • Client’s Location: Switzerland

Project Background

Rotating mechanisms, such as gears, bearings, and motors, are critical components in manufacturing processes. Unplanned downtime due to equipment failure can result in significant production losses, decreased efficiency, and financial implications.

What Was The Customer's Request?

  • The request was to create a solution for monitoring these mechanisms in order to detect potential issues and failures in advance, enabling proactive maintenance and reducing unexpected downtime.
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What Did The Client Already Have?

  • Before starting the development process, the Indeema team conducted a comprehensive analysis of the existing solutions available on the market. Furthermore, extensive research was carried out to determine the demand for a solution that caters to the specific requirements of manufacturing companies.
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Solution We Delivered

Where did we start?

We began our journey by carefully analyzing the available solutions and machinery condition monitoring case studies. Additionally, we closely studied the specific requirements of the customer in the field of vibration diagnostics. The next crucial step was to identify the best applications. We also defined the operating conditions, critical components, and potential failure modes to ensure the system's optimal performance and reliability.

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  • Requirements phase

    We identified key factors for an effective vibration measurement system: targeted frequency range, sensitivity, and environmental concerns. Following that, we carefully inspected the equipment's characteristics to ensure alignment between the accelerometer's frequency range and the expected vibration frequencies of the monitored machinery.

  • Designing System Architecture

    Attention was given to signal processing, data acquisition, device-to-server communication, visualization, pattern recognition, and reporting. The team struck a balance between performance and features while staying within budget constraints. This ensured that the hardware was as cost-effective as possible, especially given the high cost of high-performance accelerometers. The diagnostic results met ISO standards, ensuring precision and reliability.

  • Specification phase

    Comprehensive documentation of iReDS's features involved critical steps. Hardware requirements encompassed accelerometer characteristics, sampling rate, resolution, signal filtering/conditioning, and controller processing resources. Software requirements included analysis techniques, supported platforms, visualization capabilities, connectivity, UI customization, and compliance standards.

Our Development Process

  • EMBEDDED DEVELOPMENT AND ASSEMBLY

    While developing the embedded software for the condition monitoring case study, the Indeema team prioritized the design of an efficient interface with the multichannel accelerometer sensors. This involved reading raw data from each channel and implementing the required communication protocols. Calibration and self-diagnostics routines were essential components of the firmware to guarantee the accuracy and reliability of accelerometer measurements.

  • SYSTEM'S COMPONENTS INTEGRATION

    With the help of precise mechanical drawings, the engineers carefully installed PCBs and components within the enclosure. After that, they proceeded to connect the sensors, route the cables, and carried out thorough verifications and tests. The diligent approach ensured that the system's components were successfully integrated.

  • UX/UI DESIGN

    A critical objective for the Indeema team was to create an intuitive interface that effectively presented live sensor data, allowing users to efficiently interpret vibration information. This interface's centerpiece was a comprehensive dashboard that provided a concise summary of vibration data, diagnostic advice, and alerts. The team prioritized a smooth user experience by reducing the steps required to complete common tasks within the vibrational diagnostic software. This emphasis on user-centric design ensured a smooth and user-friendly experience, enhancing the iReDS IoT Solution's usability and effectiveness.

  • WEB DEVELOPMENT

    Adhering to user-centered design principles, the Indeema team developed a robust web component for the iReDS. This platform gave users a powerful and user-friendly interface for managing and analyzing vibration data. The team created an infrastructure capable of handling large amounts of vibration data. Users now have advanced options, such as using cloud-based machine learning techniques to analyze and predict vibration patterns and potential faults.

  • DEVOPS AND CLOUD ENGINEERING

    This stage included configuring servers, networks, databases, and cloud services. The team ensured optimal availability, scalability, and security for the system's operations by carefully selecting suitable cloud services and determining resource requirements. The team's expertise in infrastructure setup and configuration was critical to the vibration diagnostic system's reliable and efficient operation.

  • SOFTWARE TESTING

    The Indeema team's dedicated QA engineers played a vital role in guaranteeing the functionality, performance, and reliability of the iReDS IoT Solution. They conducted comprehensive tests, including input signal validation, load testing, usability tests, and workflow assessments. Additionally, the QA team verified the accuracy and completeness of user documentation, help files, and tutorials associated with the vibration diagnostic system.

The Team Involved In The Project

WEB Developers

3

Hardware Engineer

1

Firmware Engineer

1

Embedded Engineers

2

UX/UI Designers

2

QA Engineers

2

Project Manager

1

Project Challenges And Our Suggestions

  • Algorithm development for analyzing vibration signals:

    One of the main challenges was to develop robust algorithms that could accurately analyze vibration signals and compare them against standard levels. To overcome this, our team conducted extensive research and experimentation to fine-tune the algorithms. We used signal processing techniques and statistical analysis to find patterns and deviations in the vibration data, which helped us detect possible mechanical problems.

  • Machine learning and big data analysis for predictive maintenance:

    Another challenge was to incorporate machine learning and big data analysis into the system to enable predictive maintenance. By analyzing historical vibration data, our team developed models that could predict potential mechanism issues before they occur. This involved training the machine learning algorithms with labeled data and continuously updating the models to improve their accuracy over time.

  • Building a secure and durable software-hardware infrastructure:

    Our team implemented robust security measures, including encryption and authentication protocols, to protect the integrity and confidentiality of the data collected and transmitted by the system. We also rigorously tested the hardware components to ensure their durability and reliability in harsh industrial environments.

  • Implementing direct alarms for unpredictable issues:

    Our team incorporated direct alarm systems designed to promptly notify operators or maintenance personnel in case of any abnormal events or anomalies. This involved integrating sensors and real-time monitoring capabilities into the system to detect and respond to such events immediately.

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Impact

The iReDS IoT Solution for Rotating Machinery offers significant business benefits to clients in Switzerland. iReDS efficiently processes vibration data in accordance with machinery operation standards by utilizing advanced algorithms and industry-standard methodologies. The vibration monitoring case study presents the following business value:

  • Comprehensive Condition Assessment:

    iReDS enables a holistic evaluation of mechanical units by detecting both distributed and developed defects. It identifies issues such as shaft imbalance, bearing ring misalignment, attachment problems, lubrication issues, localized bearing ring defects, and gear tooth wear in gearboxes.

  • Issue Detection and Downtime Reduction:

    The system generates detailed reports that provide insights into the machinery's health status, potential issues, and maintenance requirements. This allows operators and maintenance teams to proactively address problems and minimize costly disruptions.

  • Preventive Action and Timely Maintenance:

    With iReDS, clients can take prompt action based on the reports, addressing maintenance requirements and resolving potential issues before they escalate. This proactive approach helps prevent costly breakdowns and optimize equipment performance.

Before And After Cooperation With Indeema

Before:

Before seeking out an IoT development company, a client hailing from Switzerland encountered several manufacturing issues. Among these, a significant challenge was the issue of downtime, which resulted in financial losses. It was determined that adopting new business models would be necessary to enhance the efficiency of manufacturing facilities and minimize downtime.

After:

By partnering with Indeema to develop the iReDS, the client received an innovative and reliable IoT solution that significantly reduced unplanned downtimes, improved efficiency, and provided scalability and customization options

The iReDS incorporates highly durable sensors that are designed to withstand the harsh conditions often encountered in industrial environments, capturing three-vector vibration data for accurate and reliable measurements.

The system includes a preliminary data processing hub, which efficiently filters and organizes the collected information for seamless data processing. The product offers the choice of local or cloud-based big data processing software, ensuring scalability and optimal performance.
The interface provides an intuitive and straightforward user experience, making it accessible to users with varying levels of technical expertise.

Furthermore, the product's customizable nature allows businesses to tailor the system according to their specific requirements, adjusting the sensitivity of the sensors, fine-tuning the data processing parameters, or customizing the reporting format.

Technical Highlights

Technologies

C++

QT

Analog & Digital Signal Processing

Custom Algorithms

Mathematical Methods

Spectrum

Correlation

Fourier Transform

Silicons

Microchip ATmega328P

Analog Devices ADXL345

Customer Success Stories

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Would you like to discuss the remote vibration monitoring case study?

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