Predictive Maintenance System - KRS INDUSTRIAL CONTROL SYSTEM CO., LTD

About the project

Date: 2025
Client: Industrial Plant Service Contract
Category: Maintenance Service, SCADA & HMI
Address: Nakhon Ratchasima, Thailand

Project Information The Predictive Maintenance System moves the plant from fixed interval servicing to condition based servicing. Wireless sensors combining vibration and temperature are mounted on the drive end and non drive end bearings of critical motors, reporting continuously through an industrial gateway and 4G router to a condition monitoring platform that plant staff reach from a SIMATIC HMI panel on the floor or from a browser anywhere on the network. Our scope covered selection of the machines to monitor, sensor mounting and commissioning, gateway and network setup, baseline measurement, alarm threshold configuration, and training the maintenance team to read trend, spectrum and time waveform so that a warning can be traced to the component that is actually failing.

Benefits of Project

Developing faults detected weeks before they cause a breakdown
Maintenance planned into shutdown windows instead of emergencies
Bearings and couplings replaced on condition rather than on a fixed calendar
No cabling to the measurement point, so installation does not stop production
Machine health visible to the maintenance team and to management at the same time
Objective vibration and temperature history to support equipment replacement decisions

Technologies We Used

Wireless vibration and temperature sensors, one unit per measurement point
Triaxial measurement: X, Y and Z acceleration and velocity
Envelope measurement for early bearing fault detection
Industrial gateway in a stainless enclosure with external antennas
Teltonika RUT950 industrial 4G router for remote data transfer
SKF Insight IMS condition monitoring platform
SIMATIC HMI panel for plant floor access to the dashboard

Condition Monitoring Without New Cable

Each measurement point carries a single wireless sensor that combines vibration and temperature in one housing, mounted on the motor bearing at the drive end and non drive end. Readings travel to a gateway in a stainless enclosure with external antennas, and from there over an industrial 4G router to the monitoring platform. Because nothing has to be wired back to a panel, sensors can be added to a running machine and the system can be extended one point at a time.

From Health Status to Root Cause

The dashboard ranks every monitored asset as Good, Satisfactory, Unsatisfactory or Unacceptable, and separates alarms into Need Action and Need Attention so the team knows what to look at first. Behind that summary sits the full diagnostic picture: long term trend, FFT spectrum, time waveform and envelope for each axis, plus temperature and sensor battery level. That is the difference between knowing a machine is getting worse and knowing which bearing is failing.