Remote Monitoring of Equipment Operations: How IoT Transforms the Maintenance of Machines, Equipment, and Devices

Equipment monitoring helps ensure that machines and devices operate correctly, minimizing the likelihood of breakdowns. Modern technologies enable monitoring without the need for physical presence or site visits to the locations of machines and devices.

Monitoring temperature, vibration, operating time, load, and noise helps determine the condition of the equipment or its components, as well as predict potential failures and identify their causes.

This approach allows for a shift to predictive maintenance, which helps reduce the costs of keeping machines, tools, and devices operational.

Remote monitoring of equipment operations is based on Internet of Things (IoT) technology, which collects and analyzes metrics in real time.

Elements of IoT

1. Connected Devices. These devices are equipped with sensors and can transmit data about their condition. Specialists access this information through a centralized platform.
2. Data Transmission Infrastructure. Devices connect to the network to exchange metrics. The following technologies are used:

   Technology	Features
   Wi-Fi	High data transfer speed, extensive indoor coverage, limited range.
   Bluetooth	Low energy consumption, short range, ideal for low-power devices.
   Private 4G Cellular	High speed and reliability, suitable for remote locations, higher connection costs.
   Public 4G Cellular	Available in most regions, good data transfer speed, dependent on operator coverage.
   Private 5G Cellular	Very high data transfer speed, low latency, suitable for critical applications.
   Public 5G Cellular	High speed and low latency, ability to connect many devices, dependent on operator infrastructure.
   Low-Power Wide Area Networks	Low energy consumption, battery longevity, suitable for mass connectivity of IoT devices.

3. Analytics and Applications. Collected data is stored and analyzed using specialized software. This allows for process optimization, maintenance planning, and improved product quality.
4. Data Storage Solutions. Special systems are used for storing large volumes of data. They ensure data protection and availability for analysis, minimizing the risk of information loss.
5. Human Interaction. People play a key role in the IoT system. Operators use their knowledge to analyze data and make decisions, managing devices remotely.

Example of Using IoT for Monitoring HVAC Systems.

Problem: Downtime and expensive repairs of climate control equipment. Downtime adversely affects climate conditions in offices, residential and industrial spaces, and warehouses. High maintenance costs increase operational expenses.

Solution – remote monitoring of equipment operations. Maintenance can be scheduled at convenient times (weekends, end of the workday) if there is information about equipment malfunction, such as abnormal vibrations, increased energy consumption, or lack of mode changes. Such metrics could help reduce repair costs, as the failure of one component can lead to the breakdown of others. The information about system operations needs to be collected at equipment installation sites and transmitted to operators who monitor the functioning modes of the devices.

To collect and process this information, a tool is required which:

• collects and processes data;
• ensures storage;
• displays data;
• notifies users of threshold value exceedances;
• generates commands for the equipment.

Results of System Implementation:

1. Reduced Maintenance Costs: Analyzing information in advance identifies potential problems that require costly repairs and equipment downtime.
2. Reduced Downtime: Early monitoring of equipment conditions identifies possible faults, thus reducing downtime. Rapid response to anomalies ensures continuous operation of systems, which is crucial for production and commercial spaces.
3. Increased Equipment Lifespan: Data-driven maintenance helps prevent breakdowns, thereby extending the lifespan of climate control equipment.

Remote monitoring of equipment operations using Internet technologies opens new horizons for maintaining systems in operational condition. IoT not only reduces maintenance costs but also enhances equipment stability. For more details about the system follow this link.