Developing an AI/ML-Driven Preventive Maintenance & Failure Detection System

Client Overview

A fortune 500 company manufacturing large machineries for industrial applications. Company is now focussing to add value to their solution by adopting innovative ways to improve product efficiency and maintenance support for their customers in USA.

Business Challenge
  • Design and development of a Smart IoT system to identify uncertain behaviour of the system and take necessary step to prevent a sudden failure In field to prevent breakdown of the entire operation cycle
  • Maintenance prediction for the machinery
  • The system should manage multiple location centrally and should have an effective notification system
  • Improve operation efficiency of product to deliver better ROI of product
  • Immediate POC and quick time to market is a key concern for development
VOLANSYS Contribution
  • Cloud Development using IoTify Cloud Framework
    • Deployment of IoTify framework on AWS IoT Cloud
    • Dashboard customization for suitable data view with various configurable parameter to analyse system quickly
    • Different user level roles & rights for different customers, plants locations
    • Collection of various sensors (vibration, temperature.) data using CENTAURTI 200 Gateway via BLE/ZigBee/Z-Wave from different sensors connected
      with machines
    • Leveraging existing OTA management functionality for on field updates for gateway and connected devices from Cloud
    • Live alerts & notification on cloud and mobile app as well for all the configurable events
    • Automated reports of failure & for possible failure to prevent in near future
  • AI-ML Implementation for Application
    • Leveraging IoTify AI-ML framework on AWS cloud for quick development
    • Single cloud interface to collect sensor data, model training and deploying that model on gateway via OTA
    • Cloud receives real-time vibration data, temperature data, etc. Through Kinesis strimming from all the machines to train the model in real-time and
      deploy the new model as and when needed
  • Mobile Application Development
    • Quick mobile application development using IoTify SDK
    • Push notification on mobile to relevant user
    • Live reading of different sensor parameters for quick review
    • Graphical view for the sensor historical data
  • IoT Gateway Solution Development
    • Leveraging pre-integrated gateway platform with CENTAURI 200 software framework for quick solution development
    • Support of Tensor flow light to run the AI-ML model and detect anomaly
    • Gateway is transferring data from various sensor to cloud over Zigbee connectivity
    • Pre-integrated sensors are used for vibration, temperature and other parameters
Technologies | Engineering Expertise

AI/ML | IoT | Software Engineering | Cloud Engineering | IoT Gateway 

Solution Architecture

Developing an AIMLDriven Preventive Maintenance

Benefits Delivered
  • Company is able to save 50% cost in upfront research & development using IoTify Framework
  • ROI time for products is reduced by 20% with the reduction in downtime thus improving productivity
  • Improvement in service revenue due to proactive maintenance alerts to customers
  • Technological edge over competitor as they are still using old time consuming methods to deal with faults and maintenance
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