From Innovation to Implementation
Innovation is the heartbeat of industrial automation, and over the past five-plus years, we have been at the forefront of this transformative journey. In a recent webinar, our CEO Drew Allen and CTO Andy Zimmerman took a deep dive into our evolution, sharing insights, challenges, and victories in implementing predictive maintenance solutions. This blog breaks down their discussion into the five key phases of our journey.
Background (2010-2017): Setting the Stage for Predictive Maintenance
- Grace Before Predictive Maintenance: We initially made our mark with GracePort, a mechanical device designed to enhance safety by allowing access to control panels without opening them. "At the heart, our core competency was mechanical design," Drew Allen noted, emphasizing our early focus on physical safety solutions. The next significant product was the Permanent Electrical Safety Device (PESD), which transitioned us from purely mechanical to analog devices. This shift required a deeper understanding of power systems and set the stage for exploring new areas of innovation.
- Predictive Maintenance Before Grace: Meanwhile, Andy Zimmerman was immersed in research at the University of Michigan, working on low-cost, low-power wireless sensors for monitoring structural health in civil engineering applications. "We were deploying these sensors on bridges and wind turbines to detect early failures," Andy shared. His work laid the groundwork for applying similar technologies in industrial settings.
Out of the Gate (2018-2019): Embracing the IIoT Revolution
- The Time Was Right for IIoT: The convergence of advanced sensors, wireless communication, and cloud technologies made the Industrial Internet of Things (IIoT) more accessible. "The cloud ecosystem became available, and all the big tech players started offering cloud solutions," Andy explained. This technological maturity provided the perfect backdrop for us to venture into predictive maintenance.
- Where We Can Make the Most Impact: Identifying the right application was crucial. After collaborating with distributors and customers, we recognized vibration monitoring as a significant area of need. Drew highlighted, "Any rotational equipment like motors and pumps can benefit from early detection of issues through vibration analysis."
Early Lessons Learned (2019-2020): Building the Foundation
- Predictive Maintenance Is a Solution, Not a Widget: One key realization was offering comprehensive solutions rather than standalone products. "We needed to provide a complete system that accounted for unique industrial challenges," Andy emphasized. This meant engaging with customers to understand their needs and tailoring solutions accordingly.
- Control vs. Monitoring: Another important lesson was differentiating between control systems and monitoring systems. Drew pointed out, "Monitoring is inherently tricky because it's not required for the machine to function every minute, unlike control systems." This distinction influenced how we approached system integration and customer engagement.
- Get the 'Right Data' to the 'Right Place': Ensuring that valuable data reaches the appropriate stakeholders becomes a focal point. "We focused on seamless integrations, whether through PLCs, SCADA systems, or cloud platforms," Andy noted. Providing data in a usable format enhanced trust and facilitated timely decision-making.
- Our Digital Transformation: Transitioning from mechanical to digital products was a significant challenge. "Developing software is an entirely different undertaking," Drew admitted. Investing in the right talent and building internal capabilities were essential to this transformation.
Technology Differentiators (2021-2023): Leading with Innovation
- Industrial Integrations: We prioritized making our systems compatible with existing industrial infrastructure. "We developed add-on profiles for Rockwell Automation and supported protocols like EtherNet/IP™ and Modbus TCP/IP," Andy explained. This allowed for easier adoption and integration into various operational environments.
- Identifying Defects Like a Vibration Analyst: We understood that customers valued data presented in familiar formats, so we designed interfaces that mimicked traditional vibration analysis reports. "We provide data in a way that vibration analysts are used to seeing, which helps in quicker diagnosis," Drew mentioned.
What Comes Next (2024 and Beyond): Pioneering the Future of Predictive Maintenance
- Next-Generation Vibration Sensor: Looking ahead, we are excited about launching a new vibration and temperature monitoring technology. "We've achieved a tenfold improvement in RF range and battery life," Andy revealed. Enhancements like better shaft speed detection and hazardous location certifications are set to redefine industry standards.
- Batteryless IIoT: We are exploring batteryless solutions by integrating thermal energy harvesting. "We believe in a future with batteryless IoT devices powered by temperature differentials," Drew stated. This innovation promises continuous monitoring without the maintenance overhead of battery replacements.
- AI in Predictive Maintenance: Artificial Intelligence (AI) is set to play a pivotal role in our offerings. "We're working on AI-driven tools that provide explainable insights into equipment health," Andy shared. We aim to deliver trustworthy and actionable predictions about equipment failures by leveraging machine learning.
Ready to Transform Your Maintenance Strategy?
Our journey into predictive maintenance is a testament to innovation, adaptability, and a relentless focus on customer needs. As Drew aptly summarized, "We hope to be your partner in increasing reliability and reducing downtime in your facilities."
We're committed to guiding you through your predictive maintenance journey, providing solutions that meet you where you are and grow with you. Let's work together to enhance the safety and efficiency of your operations.
- 📘 Download our free eBook on predictive maintenance to explore how GraceSense can benefit your operations.
- 🛠️ Request a product demo to experience how our solutions can make your maintenance safer, smarter, and more productive.
- 📞 Contact Us: For technical support or to discuss configuration options, email us at Sales@GraceTechnologies.com or call 1.800.280.9517.
