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Challenges in the Smart Monitoring of Aggregates
Critical aggregates (system composed by several separate machines) are equipments for which every unplanned downtime causes significant non-production costs. To avoid them, many critical aggregates are today covered by aggressive and costly preventive maintenance plans.
Predictive maintenance is not very widespread because the costs of digitisation are often high. IoT solutions on the market do not cover the monitoring requirements properly, so that they should be monitored with costly cabled Condition Monitoring Systems (CMS).
Data provided by CMS Systems are complex to analyse and requires special skills.
CMS Systems based on classic vibration monitoring are well known since many years for their ability to detect issues on the shaft dynamic and bearings. But they are quite limited to detection other issues e.g on the inverters or on the mechanical seals.
GradeSens Smart Monitoring Solution
GradeSens offers a cost effective Smart Monitoring Solution for critical aggregates ensuring equivalent or better performance as CMS. Our Solution opens consequently new doors to Smart Maintenance for many aggregates.
Data collected by LYRA is structured so that it can processed by Analytics effectively. Our Analytics is configured for each type of aggregates to provide KPIs representative to their main failure modes.
For aggregates with variable loads and speeds, our Analytics combines vibration data with existing process parameters (e.g. provided by the inverter ) to build a digital twin with Machine Learning. The digital twin allows you to detect anomalies when condition data (e.g. vibration, temperature) lies outside its operating dependant expected range.
Our Analytics allows to extract features from raw data to detect specific failure modes on the rotor dynamic and bearings using our extended library of algorithmes that is continuously being updated upon our new projets.
Process Equipments with variable loads and speed
Process Equipments are aggregates consisting of motors, mechanical couplings and process equipments such as pumps, evaporators, compressors or ventilators. To monitor such aggregates effectively, we recommend to install one sensor per bearing and to collect the process data generated by the inverter when the equipment is operated under variable loads and speeds.
For such equipment, GradeSens solution allows to collect vibration and process data in a structured manner so that it can be processed by machine learning to build a digital twin of it behaviour. Anomalies on the rotor dynamic, mechanical sealing, motor, inverter or on the process can be proactively detected to allow the planning of adequate preventive measures during the next scheduled maintenance.
Our solution allows you to get a better insight about the operating condition of your aggregates as a whole, to avoid unplanned shutdown and to focus your scheduled maintenance on what really matter.