Our client is saving hundreds of thousands of pounds by monitoring the energy, temperature, noise and vibration levels of their critical infrastructure.
Problem: Massive Cost of Potential Downtime
Our client operates critical conveyor infrastructure in central London to deliver aggregates to building sites.
This complex motor and conveyor system is one of very few in the country and the largest in Central London.
Lead times on replacement motors is several weeks and such a failure could lead to hundreds of thousands of pounds in lost revenue and significant delays in London building projects.
Solution: Energy, Temperature, Noise and Vibration Monitoring
The Datore Analytics as a Service solution provides our client with the people, technology and methodology needed to collect, store, model, and analyse data for predictive maintenance of their critical assets.
We deliver actionable insights from raw data. The only thing left for our client is to act on those insights to predict and prevent asset failure.
We monitor energy consumption, temperature, noise and vibration to ensure these units run smoothly.
We communicate with the client’s maintenance ticket system to automatically raise a ticket when an anomaly is detected.
By monitoring these levels, our client can see when maintenance is required, and they can schedule that for when the equipment is not in use.
Energy Consumption Monitoring in Predictive Maintenance
Energy monitoring devices track the power usage patterns of the conveyor motors in real-time.
Our ML and AI models identify deviations from normal consumption levels that might indicate potential problems such as electrical issues, wear and tear, or inefficiencies in the system.
By catching these anomalies early, our client can schedule maintenance before a minor issue escalates into a major, costly breakdown.
Temperature Monitoring in Predictive Maintenance
Temperature monitoring systems measure the heat generated by the motors and conveyor components.
Overheating can be a sign of numerous issues, such as inadequate lubrication, excessive friction, or electrical faults.
By monitoring temperature trends, we can pinpoint components that are at risk of failure due to overheating.
Noise Monitoring in Predictive Maintenance
Changes in sound levels and acoustic patterns can indicate problems such as misalignment, loose components, or mechanical wear within our client’s conveyor system.
Early detection of unusual noises allows our client to investigate and resolve issues promptly, ensuring the machinery operates smoothly and efficiently.
This layer of monitoring enhances the overall reliability of the conveyor system and helps prevent unexpected failures.
Vibration Monitoring in Predictive Maintenance
Vibration monitoring devices collect data about amplitude, frequency, and intensity of forces that might damage the motor.
Vibration analysis allows us to discover misalignment, imbalance, looseness, or bearing wear in equipment to predict the failure, and our client to act in time to prevent it.
Our AI tracks vibration levels and notifies automatically if an anomaly occurs.
Impact #1: Significant Cost Savings with Predictive Maintenance of Critical Assets
Routine and unnecessary maintenance has been all but eradicated as repairs are performed only when needed, based on real-time data insights.
This not only cuts down on maintenance expenses but also prevents expensive emergency repairs and massive downtime costs.
Additionally, extending the motors’ lifespan by addressing issues proactively leads to even bigger long-term savings.
Impact #2: Reduced Risk of Failures for Enhanced Workplace Safety
Early detection of potential issues prevents catastrophic failures that might pose safety hazards to employees and the environment.
Ensuring assets are in optimal condition enhances our client’s workplace safety and helps in complying with health & safety regulations, thereby protecting both employees and our client from potential liabilities.
It was important to our client to have a flexible solution that could provide multiple data analysis across the entire site and across their entire portfolio.
Installing different hardware and routers to support different bespoke platforms would’ve been expensive and unnecessary.
“Datore was the only provider who could work with all of our existing data as well as provide multiple IoT data feeds on the same infrastructure and still provide the flexibility to accommodate any new systems we deploy in the future.”
Iteration: Next Steps in Predictive Maintenance
We now will be deploying additional devices across the estate as well as continuing to integrate between IoT, AI and existing software platforms.