WHAT IS PREDICTIVE MAINTENANCE?

Predictive maintenance is a cutting-edge maintenance strategy that uses data and advanced analytics to predict equipment failures before they occur. It is revolutionising the way companies approach maintenance. But what exactly is predictive maintenance?

Predicting the future

Predictive maintenance is a strategy that uses sensor data and advanced analysing techniques to predict when equipment is going to fail or needs maintenance, allowing you to act before things go south. Think of it as your weather app, but instead of predicting rain, it predicts when your machinery need maintenance.

Let's break it down

So, what are the steps of predictive maintenance? It all starts with data, lots of it. Here's a simplified breakdown:

1. Data collection: The New Current measuring hub reads the sensors attached to your assets, collecting data in real-time and tracking every event.
2. Data analysis: Data from the measuring hub is processed by our edge computer. This section of the system analyses the sensor data and other sources using a variety of techniques, including machine learning algorithms, mathematical models, and physical models, to analyse the sensor data and other sources. The system learns from historical patterns and identifies the health of your assets. All the information is securely stored on-site.
3. Visualisation: The dashboard presents clear and concise graphs and percentage indicators that represent all the data, making it easy for users to utilize predictive maintenance without requiring any additional knowledge. 

Here are a few reasons why predictive maintenance is in the spotlight: 

• Maintenance efficiency: It reduces the need for routine or preventive maintenance checks that may not be necessary, saving on resources and labour.
• Uptime maximisation: By preventing unexpected breakdowns, it keeps the production line running smoothly, ensuring maximum efficiency.
• Safety and reliability: Early detection of failures means a safer working environment and more reliable equipment performance.

Predictive maintenance can be applied to any type of machine, but it is most commonly used for rotating machines such as motors that drive gearboxes, pumps, valves, or fans. In fact, it is highly effective in preventing the most common failures in this type of machinery:

Misalignment

Misalignment indicates when components that are supposed to be parallel or perpendicular to each other are not properly aligned. This can cause uneven wear and tear, increased vibration, and eventually lead to equipment failure. New Current uses vibration analysis to identify misalignment before they cause any damage.

Imbalance

Imbalance indicates the uneven distribution of mass within a rotating component, causing it to wobble as it spins. This can lead to excessive vibration, noise, and premature wear. New Current detects imbalances allowing for adjustments before the imbalance leads to more serious mechanical issues.

Looseness

Looseness indicates that a component within the machinery is not properly secured, which can result from normal wear and tear or improper installation. This condition can cause parts to move or vibrate excessively, leading to damage. New Current techniques help in identifying loose components so they can be tightened or replaced.

Bearing wear

Bearing wear involves the deterioration of the rolling elements and races within a bearing, a critical component in reducing friction between moving parts. Symptoms include increased vibration and heat, leading to potential failure. New Current employs techniques to spot early signs of bearing wear.

Stator wear

The stator is a stationary part of an electric motors. Deterioration can affect its efficiency and performance. New Current uses electrical and vibration analysis to identify stator problems such as insulation failure or physical damage.

Rotor wear

The rotor is the rotating part of an electric motor. Wear can result in imbalance, reduced efficiency, and eventual breakdown. New Current methodologies, including vibration analysis, can detect signs of rotor wear early on.

Insulation wear

Insulation wear is the degradation of the electrical insulation around conductors. This can lead to short circuits, electrical leaks, and reduced efficiency. New Current can detect insulation wear preventing potential electrical failures.

Load wear

Load wear of gearboxes, pumps, valves, or fans can manifest as erosion, corrosion, fatigue, abrasion, or leakage, each impacting the efficiency, reliability, and lifespan of these devices. New Current determines the status of these loads through the sensors mounted on the motor. This provides valuable insight and enables you to take action at an early stage. 

New Current offers a complete service for the transition to predictive maintenance. We take care of the complete implementation and keep the system up to date. Contact us about the endless possibilities.