OVERVIEW A High-Level Introduction

to the Industrial Internet of Things

REMOTE CONDITION MONITORING

For Electric Motor and Drive Systems
INTRODUCTION CONTRIBUTORS
This overview of remote condition monitoring for electric motor and drive systems This document was developed with guidance and input from members of
gives EASA members a high-level introduction to the industrial internet of things (IIoT). EASA’s Ad Hoc Committee on Emerging Technologies.

Remote condition monitoring is much more than just hardware, sensors and gate- Committee Chair
ways. This overview will not only introduce you to the hardware side, but also to Justin Hatfield
the other main factors that must be considered for a successful IIoT program. This HECO — Kalamazoo, Michigan, United States
overview contains sections on:
Committee Coordinator
• Maintenance Philosophies
Paul Rossiter
Takes a look at the different philosophies and IIoT’s impact on them. Energy Management Corp. — Salt Lake City, Utah, United States
• Business Models
Explores the many business models that can create success in IIoT, as well as the Committee Members
pros and cons of each approach. Lloyd Edward Clark, III
Blue Ridge Electric Service — Winchester, Virgina, United States
• Software /Data Platform
George Flolo
Explains the main factors impacting the data and software side of IIoT solutions.
The Flolo Corp. — West Chicago, Illinois, United States
• Hardware Selection
David Griffin
Illustrates sensor and gateway infrastructure and flow, as well as the many potential
plant equipment and process metrics that can be monitored. CPM Engineering, Ltd. — Trafford Park, Manchester, United Kingdom

Michael Huber
American MTS — Monroe, North Carolina, United States

Iain Jenkins
Jenkins Electric Co. — Charlotte, North Carolina, United States

Bjorn Eirik Mjaatveit

EMR Consulting AS —Bergen, Norway

Thomas Schardt
Nidec Motor Corp. — St. Louis, Missouri, United States

Michael Sonsogno
Smartricity Inc. — Ballinafad, Ontario, Canada

Gene Vogel
EASA — St. Louis, Missouri, United States

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INDUSTRIAL INTERNET OF THINGS (IIoT) — MAINTENANCE PHILOSOPHIES
Philosophy Simple Definition Pros Cons IIoT Effect On This Philosophy

Risk-Based & Maintenance and engineering • Reduces maintenance long • Requires engineering effort Advanced analytics identify areas of maximum potential savings.
Reliability-Centered to identify and eliminate failure term beyond typical maintenance May encompass all the other philosophies (e.g., could have
Maintenance modes • Extends equipment life personnel some machines that run to failure and others that are carefully
(RBM & RCM) monitored and maintained).

Maintenance using simulation
modeling to adjust equipment
operating parameters and push
Prescriptive run time out beyond predicted
Maintenance failure date
(RxM)
RBM & RCM may encompass all of these
• Early fault prediction • Up-front setup fees for As data collection capability increases, so does the analytical
• Root cause detection and hardware complexity needed to interpret the information and deploy effective
elimination • Monthly monitoring fee for AI solutions. RxM is driven by prescriptive analytics, algorithms,
predictions and artificial intelligence (AI) that go beyond predicting events,
• Maintenance performed only
allowing maintenance teams to explore multiple hypothetical
when needed and planned
maintenance scenarios and simulations without having to
• No need for internal/external
experience each one in real life.
data analysis resources
• Load optimization predictions

Maintenance based on • Early fault detection • Resource intensive IIoT-based PdM / CBM enables you to monitor, maintain, and
a monitored parameter • Root cause detection and • Need heavy continuous optimize assets for better availability, utilization and performance.
Predictive
(temperature, vibration, etc.) elimination analyses Real-time monitoring and notifications provide better visibility into
Maintenance
that indicates condition (with an • Maintenance performed only • Historically these functions assets, allowing you to predict failures, identify parts that need
(PdM)
IIoT spin) when needed and planned are performed via route- replacement, schedule maintenance and repairs, or take quick
a.k.a. action to extend the life of your equipment.
• Avoids unexpected based data collection
Condition-Based breakdowns • Investments in instruments,
Maintenance sensors and training
• Avoids unexpected downtime
(CBM)
• Does not always detect the
root cause

Maintenance based on time • Fewer coincidental • Unnecessary maintenance Time is not the most reliable maintenance criteria, since so
Preventive intervals breakdowns • Unnecessary maintenance many other factors can create issues for a machine. IIoT can
Maintenance • Less downtime can introduce new faults complement the PM schedule by showing machine condition
(PM) • Better than doing nothing regardless of the time since last maintenance. This may prompt
you to speed up or slow down your PM schedule.

Maintenance performed only • Maximum machine use • Lots of breakdowns You can still wait for breakdowns, but with IIoT you can see them
Run to Failure when breakdowns occur • No extra resources • Long downtime coming and be prepared.
(RTF) • Expensive repairs
• Low efficiency

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MAINTENANCE PHILOSOPHIES — Continued
ADDITIONAL RESOURCES
EASA
• https://easa.com/resources/emerging-technologies

PLANT SERVICES
• https://www.plantservices.com/articles/2019/what-makes-a-condition-based-maintenance-program-sink-or-swim/

UPKEEP
• https://www.onupkeep.com/learning/maintenance-types/run-to-failure-maintenance
• https://www.onupkeep.com/preventive-maintenance#types-of-preventive-maintenance
• https://www.onupkeep.com/maintenance-glossary/prescriptive-maintenance

FIIX - A ROCKWELL AUTOMATION COMPANY

• https://www.fiixsoftware.com/blog/run-failure-make-part-maintenance-planning/
• https://www.fiixsoftware.com/maintenance-strategies/preventative-maintenance/

RELIABLE PLANT
• https://www.reliableplant.com/condition-based-maintenance-31823
• https://www.reliableplant.com/Read/12494/preventive-maintenance

IT CONVERGENCE
• https://www.itconvergence.com/blog/5-benefits-iot-based-predictive-maintenance/

FASTRAK SOFTWORKS, INC.

• https://ftmaintenance.com/maintenance-management/what-is-condition-based-maintenance/

ACCENDO RELIABILITY
• https://accendoreliability.com/run-failure-viable-option/

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INDUSTRIAL INTERNET OF THINGS (IIoT) — BUSINESS MODELS
Model Description/Includes Non-EASA Member Competition Pros Cons Risk /Reward

-
Sell the equipment and /or • Power transmission (PT) houses • Easy to get started • Lots of competition
• EASA Member
software. Generally an upfront • Motor OEMs • Shorter sales cycle • Upfront costs
Hardware/ provides less
purchase of equipment and a • Sensor manufacturers
Software Sales value
minor software fee per month /
• IIoT firms • Lots of
year.
competition
• Less risk to the

PROGRESSION
Hardware and software costs • Sensor manufacturers • No upfront costs • Clients not used to EASA Member
per month (recurring) with • IIoT firms subscriptions
Subscription
little or no upfront costs,
similar to leasing equipment.

Monitoring and analyzing data • Vibration analysis providers • Selling a service • Loss of internal
Consulting/Data gathered by sensors and then • Customers’ internal vibration teams (higher margins) vibration analysis
Analytics applying your expertise. • EASA member can jobs
validate findings

Customizable packaged • Facilities management providers • Customer becomes • Longer sales

deals with other offerings • OEMs dependent on you cycle with many
from the company. Could be • Reduces your complexities
Risk & Reward a fixed or variable monthly operating costs by • Customer expects
(Package/ fee that is designed to avoid utilizing personnel on continual cost
Contract) failures. This is generally issues only reduction every year
part of a larger contract. You • EASA Member

+
can encompass a win/win provides more
scenario in the package. value
• Customer is tied
Only pay when the equipment • Facilities management providers • Customer only pays • Many variables for to you
Power by the
is running. Provider supplies • OEMs when a machine is why a machine may • Less competition
Hour /Equipment
not only the sensor and online be offline • More risk to the
as a Service
software but also the rotating EASA Member
(EaaS)
equipment it is installed on.

NOTES
NOTES
• • Variations
Variations/uniqueness
/uniqueness — —There
Thereare
arecountless
countlessways
waystotocombine
combineand andcreate
createhybrid
hybridbusiness
businessmodels
modelsofofall
allofofthese.
these.TheTheEASA
EASAmember
memberhashasthe
theunique
uniqueability
abilitytotoprovide
providehands-on
hands-onservice
serviceand
andcorrective
correctiveactions.
actions. Consider
Consider partneringpartnering with someone
with someone that one
that provides provides onebusiness
of these of these models
businessbutmodels
may notbuthave
may anot have a presence
business business presence in your geographic
in your geographic area. area.
• • Data
Dataintegration
integration——Whether
Whetherorornot
notdata
dataintegrates
integratesinto
intoother
othercustomer
customerinternal
internalsystems
systemsmaymaybebeaafactor
factorininallallofofthese
thesemodels.
models.
• Guarantees — Any of these models can include guarantees of varying complexity (e.g., uptime
• Guarantees — Any of these models can include guarantees of varying complexity (e.g., uptime guarantees). guarantees).

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INDUSTRIAL INTERNET OF THINGS (IIoT) — SOFTWARE /DATA PLATFORM

SENSORS & GATEWAYS

(Hardware)

DATA PLATFORM*

Integration/ API Data Artificial Trend Plots Analysis Plots Notifications/

Connecting to internal or Harmonization & Intelligence / Sensor data tracked and Plots used for analysis, Alarms
external IIoT systems or a Processing Machine Learning plotted over time. such as FFTs or time Asset health notifications
SCADA (supervisory Data and time stamps The platform analyzes waveform plots. provided as required.
control and data must be recorded the machine and /or
acquisition) system properly and converted to process.
with third-party platform usable data.
providers.
Stakeholders Stakeholders Stakeholders Stakeholders Stakeholders Stakeholders
EASA Member EASA Member EASA Member EASA Member EASA Member EASA Member
Analysis Provider† Analysis Provider† Analysis Provider† Analysis Provider†
Customer

* Cybersecurity should be a consideration for any data platform. Data access

(role-based permissions) and data ownership should be considered.
Software fees (licensing) may also apply.
ACTIONS!
Stakeholders
†
EASA Member may also be the Analysis Provider, as could an internal customer
EASA Member
team. These are not mutually exclusive.
Customer

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INDUSTRIAL INTERNET OF THINGS (IIoT) — HARDWARE SELECTION
TRANSFORMER VFD MOTOR DRIVEN EQUIPMENT PROCESS PLANT
EXAMPLES Current Current Current Magnetic flux Vibration Process counts Asset location
OF POSSIBLE Load balance Load balance Voltage Ultrasound Temperature Motion detection Air quality (e.g., CO, CO2)
Voltage Frequency /speed Speed Acoustic emissions Ultrasound Fluid, gas flow /pressure Humidity / dew point
SENSOR Magnetic flux Harmonics Vibration Partial discharge Pressure Fluid usage Noise level
MONITORED Vibration Temperature Temperature Particle wear Flow Doors open /closed Thermography
Partial discharge Vibration Particle wear Analog output devices Water detection
METRICS Digital /contact closure

Sensors Gateway /Router Sensor data routed via gateway or

Communication Purpose
Sensors are typically wireless, wired via ether- Gathers data from the sensor(s) and mobile phone / tablet via Bluetooth.
net, or wired to a wireless hub. sends it to the cloud or an internal
Power server. The gateway may just be a data DELIVERY OPTIONS
Typically powered by batteries (rechargeable, hub /communication tool but may also
replaceable or non-replaceable). Wired sensors store and analyze data.
usually do not require batteries and may be Communication
powered directly or by PoE (power over ether- Can be done using Wi-Fi, ethernet or
net), or by harvesting a machine’s wasted heat a cellular network. The easiest option
or vibration energy. is to be independent of the customer’s
Mounting network and transmit data out via cellu-
Sensors can be mounted in many ways and lar network. Additionally, some sensors
places. To detect bearing defects, mount as can act as routers to create a self-heal- Mobile device Local or remote Cell tower or ethernet
ing mesh network that amplifies the
close to bearing as possible. Avoid mounting to
gateway’s range. used by technician* customer-controlled
any flexible cover (e.g., fan cover). Some man-
ufacturers mount combination sensors in the Power server(s)*. Data delivered
middle of the motor frame and collect various Typically directly powered or by PoE via network or manually
readings from one location. (power over ethernet).
uploaded.
Data Alternative
May just gather raw data or may include edge In some systems, mobile phones can
computing that reports or analyzes events at act as a gateway when within range of
the sensor level. a sensor. * All delivery options provide some level of data storage,
viewing, analysis or notifications. Cloud/computer*

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Copyright © 2022, EASA, Inc. (Version 0622)