Implementing Vibration & Thermal Anomaly Detection on Industrial Motors
Dr. Ananya Rao
Lead AI & Analytics Researcher
1. Fast Fourier Transform (FFT) Edge Analysis
Piezoelectric accelerometers capture high-frequency vibration up to 10kHz. The edge gateway performs on-chip FFT analysis to detect characteristic bearing inner and outer race fault frequencies.
- Early micro-fracture detection 3 to 6 weeks before audible noise occurs
- Automated temperature rise correlation over RS-485 Modbus probes
- Reduces catastrophic motor replacements by over 70%
Deploying AI on operational data shifts maintenance teams from stressful emergency repairs to predictable, planned maintenance windows.
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