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IIoT Enabled End-to-End Solution

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IIoT Enabled End-to-End Solution

Today, industry 4.0 is primarily driven by digitalization and connectivity. With IIoT and Cloud being the key enablers, Maintenance 4.0 is the starting step for Industry 4.0. It involves continuous monitoring of machine health through sensorization and the use of edge-computing for smart analytics and diagnostic, discerning faults at a very early stage. It’s like detecting cancer at stage zero!

The Neptunus Vision

  • With our cutting edge technology, combined with the fundamentals of mechanical engineering and the latest diagnostic technologies, our focus is to empower plant operators to detect emerging faults in their equipment, several months in advance.
  • By combining our expertise and experience, we aspire to make asset performance analyzable, monitorable, and integrated across all our customer’s machine units. All of which are ultimately geared towards running a reliable, profitable, and sustainable plant.

The Neptunus Solution

Neptunus’s ARM solution is geared towards detecting issues with machines at a micro level and not only at a macro level. The addition of IIoT & cloud enablement makes the machine health data available for remote monitoring via intuitive and customizable dashboards. Conventionally, predictive maintenance solutions are applied for “spot” monitoring of individual critical machines. Our ARMs brings about a revolution by custom engineering the solution for a complete process/ value chain as an end-to-end solution.

Knowing early on that the bearing is in the critical alarm stage is more helpful than a detailed analytics report that pinpoints what is wrong, just before the bearing fails. Time is the essence here!  

To get the optimal results with a justified ROI, we deploy an IIoT enabled end-to-end solution across the process line. This is an evolution over the earlier contemporary practice of conducting predictive maintenance only at an ‘equipment’ level and using a spot solution.

An Overview of Our End-to-End ARM Technology

Using the power of IIoT & Cloud technologies, the ball mill application displays our end-to-end ARM solution in action. Our customized detailed engineering solution has been designed and implemented to enhance the reliability of the ball mill in an Aluminum processing plant.

As shown in the schematic diagram:

  • The system uses different online sensors like torsional vibration, oil quality management, pressure, and the temperature on various critical machines to map their health in real-time (sensors indicated in green and red).
  • Edge computing devices process this data in the field and the output is sent using an IIoT platform to the cloud-based dashboard.
  • This dashboard can be viewed remotely by all relevant stakeholders, from the maintenance team in the plant to the COO in the head office.

Example of the Motor Diagnostic Dashboard

Want to get a hands-on feel and experience of the dashboard? Click here to get a live demo.

Salient Features of Neptunus’ IIoT & Cloud Solution

  • The entire system is designed from the grounds-up and has an ‘operator-centric approach.
  • Our sensors provide data via real-time stats. They are geared towards monitoring the entire plant and finding the minutest faults in advance. It’s like detecting cancer at stage 0!
  • The diagnostic displays vital information such as analytics, alarms, and the overall dashboard is simple enough for a machine operator to understand and take action.
  • Unified indexes, color-coded status alarms, and singular parameters are displayed instead of fancy complex curves, waveforms, and multiplexed displays that require an ‘expert’ to read and explain.
  • Recognized amongst the top 10 IIoT solution providers in India by CIO Review magazine.

Benefits of Neptunus’ IIoT Enabled End-to-End Solution

1) Condition monitoring or predictive maintenance addresses the core problem of maintenance: Fix the correct part, in the correct place at the correct time.  

2) It can cut down overall maintenance costs by 5-10%.

3) Reduces the time required for planned maintenance by 20-50%.

4) Improves the performance of assets and increases production efficiency.

5) Reduces ecological footprint by controlling and gauging energy consumption.

6) Enhance work production, operations, and safety.

7) Increases asset availability and uptime by 10-20%.