IIoT Solutions Delivering Significant Benefits 

Challenge:     
Ore build-up on the vibratory feeder pan frequently caused contact with the static chute, leading to structural cracks and catastrophic failures. Each failure resulted in ~6 hours of lost production plus repair costs.

​

Solution:     

Shortly after installation, two chutes on separate dates triggered notifications of rising velocities. Upon inspection, the maintenance team identified build-up at the back and sides of the feeders, leading to increased vibration. Preventative cleaning of the chutes was performed, averting potential structural failures.

Challenge:     
The client was experiencing unplanned downtime on at least three (3) occasions in the past year.  Estimated $250,000+ loss in revenue each day of downtime.

Solution:     
IIoT sensors were installed within the operating power generation facility.  The technology detected a start of vane pump failure within six (6) weeks of installation.

Challenge:     
The client needed a reliable solution to identify and address potential bearing defects on critical conveyors within their Outflow Circuit. There were concerns of unplanned downtime and costly production losses and repairs.

Solution:     
The Wireless vibration monitoring system was installed on their conveyor network. These sensors, integrated with predictive analytics, flagged an emergent condition on a conveyor’s pulley. The condition monitoring team confirmed the sensor's alert, allowing for early detection and proactive maintenance, thus preventing a potential failure and supporting their data-driven decisions process.

Challenge:     
Effective condition monitoring is crucial to prevent unexpected equipment failures and reduce downtime. The client needed a reliable system to detect potential bearing faults in critical equipment, particularly those in areas not readily accessible or in hazardous locations, before they could cause extensive damage.

Solution:     
The IIoT sensors autonomously identified a fault pattern in the Motor DE bearing, specifically pinpointing the type of bearing fault (BPFO). This early detection allowed for timely, data-driven maintenance decisions, preventing the possibility of extensive damage and affirming the value of the IIoT solution.

Challenge:     
The client faced a significant risk of undetected equipment issues due to reliance on manual monthly monitoring. A layshaft bearing on a crusher, offline for a modular shutdown, showed a sudden increase in vibration, which could lead to catastrophic failure if not addressed promptly.

Solution:     
An IIOT sensor detected the vibration increase almost immediately after the plant restarted and sent an immediate alert. The condition monitoring team confirmed the issue, identifying ore buildup inside the pulley itself. They issued a repair notice to remove the buildup, preventing potential failure and avoiding an estimated $300k in operational and mechanical losses.

Challenge:     
A Client was experiencing persistent failures in their in-plant generator. Estimated loss due to downtime with each failure: $160,000 per day.

​

Solution:     

In order to ensure the system was monitored overall and that vibration energy was not being transferred from elsewhere, IIoT sensors were rapidly deployed throughout this and other auxiliary equipment. Within 13 days, they detected a brush failure in the generator.

Challenge:     
Failures on complex baggage handling equipment have a major impact on flight schedules and passenger satisfaction. 

Solution:     
IIoT sensors were installed within their facility detecting the fault in the motor bearing within one (1) week. A basic $65 bearing was replaced during a regular maintenance shutdown instead of having a $5,000 gearbox fail during peak usage.

Challenge:     
A Client was experiencing persistent failures in two (2) of their plant motors. Estimated loss due to downtime with each failure: $150,000 per day
 

Solution:     
The Wireless Vibration IIoT sensors were installed within their facility and detected a bearing outer race failure within six (6) weeks of installation.