Nanoprecise
Applying IoT and AI to Optimize Machine Performance and Lifespan

Industrial equipment frequently operates inefficiently before breaking down, leading to increased energy consumption and production disruption. This ineffectiveness results in substantial losses. Therefore, improving equipment efficiency is crucial for achieving business sustainability. The situation raises the question of how to maintain sustainability while minimizing losses. The answer to this lies in the optimization and vigilant monitoring of equipment operations.

This led to the creation of Nanoprecise, a company that specializes in predictive maintenance solutions for industrial machinery. The company employs Energy Centered Predictive Maintenance to monitor and diagnose critical machines that keep the operations moving. It prevents production losses and ensures that manufacturing supply chains produce goods optimally.

“Our company never allows the machinery to lapse and always keeps it at its best,” says Sunil Vedula, CEO and Founder of Nanoprecise.

The company aims to determine when the machinery might fail. It believes in taking faster maintenance action to ensure the equipment runs efficiently during production. It understands that machines, like humans, exhibit certain signs when not functioning properly. To detect these signs, the company uses an IoT device called MachineDoctor.

MachineDoctor is a wireless sensor designed to be scalable and globally applicable, thanks to its ability to communicate with a global SIM card. The method is similar to smartphones and works in 175 countries with 375 telecom operators. It is engineered to collect data on six parameters. These parameters include vibration, sound, temperature, magnetic field, speed of the machine and humidity. The sensor can detect and capture data in any situation and has found applications in various sectors, including manufacturing.

Once MachineDoctor collects the data, a platform that combines AI and physics-based models named RotationLF analyzes it. It is a scalable, sensor-agnostic platform that monitors machine conditions in real-time, analyzes complex health data and predicts the remaining useful life (RUL).

The software detects anomalies, diagnoses problems related to components like bearings or shafts and predicts the remaining time to failure. It also calculates the increased energy consumption due to the fault, emphasizing the importance of maintenance to prevent unnecessary energy use.

After identifying the problem, its impacts and root cause, the software recommends actions to rectify it.

RotationLF works seamlessly with MachineDoctor sensors, receiving data through an encrypted and secured network and detecting even small changes in the machine. It is the only software that uses the sophisticated CEEMDAN algorithm for early machine failure detection. Using it enhances machine longevity, enables advanced planning for maintenance activities, prevents overload from false notifications and averts the recurrence of faults.

Our company never allows the machinery to lapse and always keeps it at its best

An apt example of this is when Nanoprecise helped Nutrien, a potash miner, improve machinery efficiency. It installed sensors on about 100 gearboxes, which were essential for Nutrien’s production. These sensors were capable of detecting even minor signs of potential failure.

Within three months, the sensors detected a gearbox issue. Earlier, such an issue would have caused 12 hours of downtime, costing Nutrien $120,000 per hour. Early detection allowed planned downtime and gearbox replacement, saving about $720,000 by reducing downtime to six hours. Thus, the company’s solution helped Nutrien prevent unexpected machinery failure, reduce downtime and save a significant amount of money.

The key differentiating factor of the company is its multidisciplinary team. It possesses a diverse array of expertise, ranging from software development and hardware engineering to sales, marketing and condition monitoring. This unique blend of skills and knowledge, coupled with business acumen, enables it to deliver a comprehensive solution that adds value to customers.

Integrating domain expertise with AI also ensures accurate and reliable machine health diagnostics, avoiding the pitfalls of data misinterpretation. This approach is instrumental in delivering a product that provides a quick return on investment.

The speed and efficiency of Nanoprecise's solution, is demonstrated by its ability to detect problems instantaneously. This agility and responsiveness set it apart in the predictive maintenance market, reinforcing its position as an industry leader.