Industrial IoT · 2024
VibrationGuard Predictive Maintenance System
An artificial ear that listens to a machine and hears a failure two weeks ahead.
Sensors that measure motor vibration 10,000 times per second, plus AI that interprets the data, give a warning two weeks before a failure happens. The result: 78% less unplanned downtime.
Live simulation
9 machines, one screen. Catch the fault yourself.
The line below simulates a real plant. Pick a machine and watch its vibration and frequency spectrum live; add a fault, speed up time and prevent downtime with maintenance.
Signals come from a physical model: imbalance shows at running speed (1×), misalignment at twice that (2×), and bearing damage at the bearing’s own frequency (BPFO). Colours follow ISO 10816-3 vibration limits.
Challenge
Unexpected failures and unplanned downtime in industrial motors.
Our solution
FFT analysis, AI-based failure prediction, 3D visualisation and OPC-UA integration. Warnings two weeks in advance.
The story
How we built it
Unplanned machine downtime costs production plants millions of dollars every year. VibrationGuard is an Industry 4.0 solution that monitors motor health and predicts failures.
MEMS accelerometer sensors collect vibration data at 10,000 samples per second. The data is split into frequencies with an FFT algorithm and fed into a machine learning model.
With 3D motor visualisation and real-time waveform analysis, operators can see motor health instantly. The system predicts bearing and imbalance failures 2 weeks ahead and connects to existing SCADA systems via OPC-UA.
Technologies used
- DSP / FFT
- Python / ML
- React Three Fiber
- MEMS sensor
- OPC-UA
- SCADA
Technical specifications
| Sensor | MEMS 3-axis ±16 g |
|---|---|
| Sampling | 10 kHz / channel |
| FFT resolution | 4096 points |
| Frequency range | 0.5 Hz – 5 kHz |
| AI model | Random Forest + LSTM |
| Prediction window | 14 days |
| Integration | OPC-UA / Modbus |
| Interface | 3D + Web + Mobile |
VibrationGuard
Tells you a machine will fail two weeks in advance.
View solutionRequest a VibrationGuard demo
If you have a similar need, let’s bring our experience to your project.