Summary: DSI Innovations partnered with a leading industrial client to modernize equipment monitoring and maintenance strategies. Using advanced Ignition-based analytics, the project streamlined data collection from motor tests and VFDs, enabling predictive maintenance and improved operational reliability while laying the foundation for future system enhancements.
Client Challenge
A major industrial facility faced challenges with manual data collection during constant speed motor testing, making it difficult to track motor and variable frequency drive (VFD) performance metrics accurately. The existing data collection processes were labor-intensive and reactive, relying on periodic inspections rather than continuous monitoring and analysis.
With no automated comparison against industry standards, early signs of equipment degradation often went unnoticed until critical failures occurred, leading to costly downtime and maintenance. Our customer needed a scalable, integrated solution that could not only collect real-time data but also turn it into actionable insights to support predictive maintenance strategies.
Our Solution
- Our team partnered with the customer to design and deploy an advanced, Ignition-based analytics system tailored to meet these challenges head-on.
- Key elements of the solution included:
- Capturing running data from constant speed motor tests by integrating internal VFD parameters and local motor input/output signals, such as vibration and temperature sensors.
- Storing this real-time data in a comprehensive SQL database for structured analysis and historical trending.
- Implementing analytics tools within the Ignition platform to compare collected data against industry standards for motor and VFD performance, automatically flagging deviations that could indicate developing issues.
- Recording analyzed data back into the SQL database and generating intuitive reports to provide visibility into individual motor and VFD performance over time.
- Leveraging the customer’s existing virtual machine (VM) cluster to securely host the Ignition and SQL servers, maximizing infrastructure use and ensuring seamless operation.
- Creating a scalable platform architecture capable of supporting future expansions, including facility-wide data models, power grid trending, and enhanced analytics tools.
We worked closely with the customer to ensure the system’s implementation aligned with production demands, integrating advanced diagnostics without disrupting critical operations.
The Results
- The Ignition-based solution transformed the customer’s approach to equipment maintenance, shifting from reactive inspections to proactive, data-driven decision-making.
- The system delivered real-time visibility into daily running conditions, capturing fault data and maintaining a comprehensive history of peak demand cycles—key for understanding equipment stress and wear.
- Graphic visuals enabled operators and maintenance teams to quickly identify signs of motor or VFD degradation, reducing the risk of unexpected failures and unplanned downtime.
- By integrating torque and angle data with advanced analytics, the system empowered predictive maintenance strategies that extended equipment life and reduced maintenance costs.
- The secure, scalable architecture laid a solid foundation for future data-driven initiatives, ensuring the facility remains agile and competitive in a fast-evolving manufacturing
Technology Used:
- Ignition
- SQL Database
- Variable Frequency Drives (VFDs)
- Vibration and Temperature Sensors
- Virtual Machine (VM) Cluster
- PLC Communication and Integration
- Custom Analytics and Reporting
