AI-based acoustic condition monitoring of industrial machinery

Project Information

Motorlisten

Grant agreement ID: 827712

DOI

10.3030/827712

Project closed

EC signature date 17 July 2018

Start date 1 August 2018

End date 31 January 2019

Funded under

• INDUSTRIAL LEADERSHIP - Innovation In SMEs

Total cost

€ 71 429,00

EU contribution

€ 50 000,00

Coordinated by

ONEWATT SOLUTIONS BV
Netherlands

Periodic Reporting for period 1 - Motorlisten (AI-based acoustic condition monitoring of industrial machinery)

Reporting period: 2018-08-01 to 2019-01-31

Summary of the context and overall objectives of the project

Globally, there are more than 300 million industrial electrical motors running. These motors consume around 70% of the power delivered to industrial facilities. They serve as the backbone of the industrial world, running 24/7 to support production lines. However, these motors experience faults which if left unaddressed, can bring a whole production line down. When this happens, the company can lose upwards of 260,000 USD per hour causing unproductive workforce, spoiled raw materials, and unsatisfied customers. Moreover, the electrical efficiency of the motor decreases over time as it experiences wear and tear, increasing energy consumption.

OneWatt developed an AI-based predictive maintenance system that listens and understands noise coming out of electrical motors. This system utilizes sensors called EARS that is totally non-invasive and non-contact, together with DSP and machine-learning it detects and predicts faults before they happen, avoiding unplanned downtime. The system also ensures that motors are working in its most efficient, decreasing energy consumption, and improving the productivity of maintenance.

The first goal is to analyze the commercial feasibility of the technology and identify which market segments, requirements, and strategies to be used. Second, identify parameters and methodologies to minimize energy consumption, increase asset lifespan, and increase reliability of predictions.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Industrial Internet of Things adoption is proving to be the next big thing in terms of revolutionizing the way industries conduct their business. The benefits are massive, both economically and environmentally. The competition is also fierce, with both established brands and startups offering different solutions, which requires OneWatt to differentiate from the rest by focusing on the needs of the Automotive, FMCG, and Wind industries. The AI and hardware were adjusted to address the needs of these segments.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

With the success of the pilots and sales, OneWatt achieved product-market fit, and continues the commercialization of the product. Market leaders expressed interest in the project, including Engie, ABB, and Advantech. Moreover, clients have been converted to paying clients.

Beyond that, the system is expected to increase the productivity of maintenance teams in industrial facility, with OneWatt performing diagnosis and detection.

OneWatt is also expected to lower energy consumption by as much as 10% equivalent to 21.6TWh per year.

Live installation of OneWatt

Live installation of OneWatt with the hub