Green Predictive Maintenance

Efficient energy management is a fundamental factor that aids businesses in minimizing energy consumption and enhancing the operational efficiency of machinery and equipment. Effectively monitoring energy consumption also serves as a critical element for accurately identifying potential issues, managing peak loads, forecasting overloads, detecting energy leaks, and addressing anomalies that may arise during production operations.

 

 

The system uses IoT technology to collect real-time motor power data and then provide analysis to improve machine efficiency and reduce motor energy consumption. This solution aims to help businesses approach Green Production and Net-ZERO emission.

Energy and cost savings: The system helps identify inefficient equipments or processes to optimize operations and energy consumption, minimize waste and reduce operating cost.

Improve operational efficiency: By monitoring the equipment in real time, the system can detect problems, breakdowns or potential problems before they have serious consequences, thereby improving performance and reliability of the equipments.

Easy maintenance and forecasting: The system allows monitoring and analysis of a motor’s operating condition, helping to predict maintenance time, replace parts or perform maintenance tasks in a timely manner. This helps avoid unexpected breakdowns and optimizes maintenance planning.

Reduce risk of accidents: The system can detect dangerous situations, such as an electric overload or overvoltage. This helps reduce the risk of accidents and protects the safety of employees and business assets.

Optimizing production processes: By monitoring motor energy consumption and performance, the system can provide data and information needed to improve production processes, increase productivity and product quality.

Remote management and online monitoring: The system allows remote management and online monitoring, helping users control engine operation anytime, anywhere. The online warning system of emergency situations helps users to promptly handle any situation in order to avoid incidents.

Provide information about engine operation:

– Total power consumption of the motor.

– Number of hours of running with load, number of hours of running without load.

– Average power of the engine (Total power consumption/hours of operation).

– Effective power of the motor (Total power consumption/hours of running the machine under load).

– Operating capacity of the engine (Total power consumption during running time with load / number of hours running the machine with load). If this number is higher than the norm, it is an indication that the machine has an abnormality (lack of lubricating oil, damaged motor or working parts ..).

– Amperage: Rated; actual average; maximum; minimum (calculated for the time the machine is running under load). This data helps to detect machine abnormalities (lack of grease, motor or working parts damage ..).

– Non-average, maximum and minimum Power Factor value.

– Average harmonic value.

– Number of incidents such as phase loss; Overload; line deviation; high voltage, low voltage, voltage deviation.

– Power consumption and electricity costs during peak hours, normal hours and off-peak hours.

– Motor operation and power consumption report.

– Equipment failure prediction report (Forecast of failure based on amperage trend).

Online problem alert via mobile application 

– Loss of power supply phase.

– Power supply voltage drop.

– Power supply voltage difference.

– Current difference between phases.

– Motor overload.

– Damage to peripheral equipment (broken coupling, broken belt, broken load chain, broken shaft).

Provide machine OEE data:

– Planned working hours, total running hours; hours of running with load, hours of idling

– OEE indecies: Norm; actual and actual % against norm.

– Equipment OEE report by period.

– Monthly OEE report.

Detect motor failure

  • In the case of motors with amperage or capacity during operation with higher than rated loads, a motor fault detection service can be provided upon request to help detect the 3 most common motor faults: Ball bearing error, Stator error; Rotor error.
  • Provide hardware.
  • Provide Instructions for installing hardware into electrical cabinets.
  • Set up data into the system and provide service accounts.
  • Provide monitoring service for engine operation and energy consumption
  • Support users throughout the service life.
  • Provide engine fault detection service (on request).

You can find software functions in details in our brochure