OEM Machine Manufacturers
Monitoring Remote Assets
Problem Statement & Background
Original Equipment Manufacturers (OEMs) are seeking a cost‐effective approach to monitoring their equipment as it is often deployed in remote locations. These machines are deployed in a wide array of situations, from traditional industrial settings to more remote mining facilities. These machines need to be under constant supervision, and the capture and storage of sensor data in a technology agnostic system are critical to making an accurate quantitative analysis of their performance. In many cases, the OEM has warranty responsibilities to uphold so that their customer’s business runs smoothly. However there are two apparent shortfalls to this approach: (a) the machines provide access to a limited amount of data; (b) the ability to collect machine data and communicate efficiently about it. In addition, these machines are often integrated with other equipment, such as pumps and motors, to perform tasks. These assets also play a key role in the performance of the machine, and their data is just as important to understand the overall effectiveness and utilization of the machine.
Proposed Solution Summary
SenseOps proposes to install an intelligent edge device in proximity to, on or in the machine to monitor all available sensor data exposed through controllers, PLCs and other data systems. The SenseOps remote monitoring solution is to install unobtrusive sensors directly on the various sources of data (pressure, temp, power, flow, etc.) and bring the real-time data to a SenseOps intelligent gateway device(s) installed at one or many sites. These SenseOps gateways acquire and store the data collected through our machine monitoring system locally, perform analytics and present the relevant information to the site host and operators on their devices (smartphone, computer, kiosk/displays). The OEM has a “fleet” view of all of the sites and can perform analytics and benchmarks to improve their availability, operating efficiency and overall equipment effectiveness. Furthermore, the condition monitoring data can be utilized for production, accounting and a wide variety of asset management reporting requirements. Utilizing predictive analytics tools and leveraging the same data can help to identify and predict trends and events, as well as machine utilization. This allows the OEM to ensure their machines perform reliably and efficiently.
Solution Scope Details
- SenseOps Gateway connects to existing PLCs, data loggers, control systems, CANBUS and other data devices.
- In addition to existing data sources, SenseOps deploys condition monitoring sensors onto previously un‐instrumented assets or at
lower levels, at as granular level as required, even down to the individual line or component level.
- SenseOps Gateway provides intelligent data aggregation and compression, with up to one-year of local data history
- SenseOps Gateway with secure login provides local/tenant visualization of the data and analytics on their
smartphone, computer and/or kiosk/display.
- Internet connectivity for the Gateway provided by 4G/LTE router can “piggyback” on existing wi‐fi, enabling OEM
visibility into individual distributed asset/machine performance.
- SenseOps Cloud Service provides aggregated “fleet” visualization, event detection, analytics and reporting
across portfolio(s) of assets.
- The entire solution is delivered and maintained “as‐a‐service” in an economical subscription based model.
- Monitor and provide direct feedback on machine performance
- Real‐time identification of events (e.g. oil cooler failure), notifications to owner, operator, site managers and
warranty providers. Notifications can be integrated into work management system(s), initiating work orders.
- Benchmark usage across deployment sites, technology types, seasonal/weather patterns. Identifying “best practices”
sites, as well as sites with significant “room to improve.” Tracking site improvements over time, and
enabling incentive/penalty-based approaches to warranty and O&M provider contracts.
- Enable OEMs to offer new customer engagement models based on utilization instead of flat lease structure.
- Engineer, Procure and Construct – Transducers, Sensors, Cabling, Gateways, Connectivity.
- Install and configure SenseOps solutions in site appropriate manner, connecting communications from existing
systems and new wired/wireless sensors to SenseOps Gateway.
- Configure 4G/LTE router and service plan.
- Configure SenseOps embedded software to collect, aggregate and analyze data. Provide local visualization of the data by users (tenants/facilities managers) in the proximal network at the facility.
- Configure SenseOps Cloud Connect to receive data from Gateways and external data sources, to enableOwner/Operator “fleetwide” analytics and visualization.
- Host, manage and maintain edge and cloud systems “as a Service.”