Converting our existing critical assets to smart assets using vibration sensors and cloud-based monitoring is a significant step towards achieving operational efficiency and improving plant availability This move aligns with the industry concept of ‘Cement 4.0’ where technology plays a crucial role in optimising industrial processes.
As part of this work, vibration sensors have been deployed on critical drives of grinding mills and kilns to provide real-time data for machine health. Sharing the details of our Maldon site grinding mill (2400KW drive), where the gearbox is being monitored through these sensors, has enabled us to predict/fault find to avoid major unplanned events over the years.
In general, below is a breakdown of the key components and benefits of this technology known as the industrial internet of things (IIOT):
- Vibration sensors: The use of vibration sensors on critical drives allows us to continuously monitor the health of these assets in real-time. Vibration analysis is a powerful tool for detecting early signs of wear, misalignment, imbalances, and other potential issues. By installing these sensors, you gain insight into the condition of the equipment and can address problems before they lead to unplanned downtime or failures.
- Gateway and 4G network: The gateway serves as the communication link between the vibration sensors and the cloud platform. It collects data from the sensors and transmits it securely over a 4G network to the cloud for analysis. Using a reliable and fast network like 4G ensures that data is delivered in a timely manner, enabling swift responses to any emerging issues.
- Cloud platform: The cloud platform is where all the collected data is stored and analysed. It leverages advanced analytics and machine learning algorithms to process the incoming information. This analysis provides actionable insights into the health of the critical drives. By utilizing the cloud, you can scale the system efficiently and access the data from anywhere, making it easier to collaborate and make informed decisions.
- Real-time alerts and notifications: The cloud platform is configured to send real-time alerts and notifications to the relevant personnel when abnormal conditions or potential issues are detected. This feature enables your team to respond promptly to anomalies and take appropriate actions, mitigating risks and preventing unexpected downtime.
- Predictive maintenance: By monitoring the condition of critical drives in real-time and leveraging the insights from the cloud platform, you can shift from reactive maintenance to predictive maintenance. Predictive maintenance allows you to plan maintenance activities proactively, reducing downtime, minimising repair costs, and extending the lifespan of your assets.
- Continuous improvement: The data collected and analysed over time can provide valuable information about the performance and reliability of critical assets. This data-driven approach allows us to identify patterns, optimise processes, and make informed decisions for continuous improvement.
Overall, embracing technology in the form of smart assets and cloud-based monitoring will undoubtedly help us achieve our operational technology roadmap objectives, boosting efficiency, availability, and product quality while reducing operational risks.