Smart Multi-Sensor Predictive Maintenance Solution for a Europe-Based Industrial Automation Leader
Overview
The client needed a real-time predictive maintenance solution for rotating equipment to detect early faults in vibration, temperature, and humidity, reduce unplanned downtime, improve safety, and provide multi-parameter diagnostics for proactive maintenance and extended machinery lifecycle
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Challenges
Lack of real-time fault detection for vibration, temperature, and humidity in rotating equipment
Absence of predictive diagnostics, leading to frequent unplanned downtime and higher maintenance costs
Solution
- Developed multi-sensor nodes integrating MEMS accelerometers, temperature, and humidity sensors for comprehensive equipment monitoring
- Implemented edge-based FFT vibration analysis and environmental thresholding to detect anomalies in real time
- Configured automated alerts using standard industrial wired and wireless protocols for seamless integration
- Delivered actionable insights enabling predictive maintenance and optimized maintenance planning
- Designed for low-power operation, long-term deployment, and scalability across diverse industrial assets
- Built modular firmware supporting easy customization, secure local preprocessing, and future feature upgrades
Outcomes
- Reduced unplanned downtime by 22% with early detection of mechanical and environmental anomalies, improving overall equipment reliability
- Lowered maintenance costs and enhanced safety through actionable multi-parameter insights, enabling proactive maintenance planning and extended machinery lifecycle
