Industrial Internet of Things-based Predictive
Maintenance for Equipment Protection
1st Yasser N Aldeoes 2nd Dr. Prasad Gokhale
dept. Computer Engg, dept. Computer Engg,
Vishwakarma University Pune, Vishwakarma University Pune,
India
Prasad.gokhale@vupune.
yasser.aldeoes-043@vupune.ac.in
Abstract: This article provides a brief overview of each
approach that should be included in a predictive maintenance
program for typical facilities, as well as basic inspection
procedures that can be used to reduce field time. Often,
improper and unnecessary maintenance may result in wasted
resources, time, and money. Industry 4.0 has developed a
methodology that can be used to lead maintenance from failure
to success. In this paper, a safe and fast method of analysis for
predictive maintenance is used. This method is called infrared
imaging. It is based on image processing and statistical
methods, in which the temperature of the hot spots of the
bearings during work is compared with the reference
temperature. The application of predictive maintenance has
become an essential part of all production and industrial fields,
including general machinery and the petroleum sector, and gas
and power generation, and water plants, petrochemicals. All
these industries need to successfully implement predictive
maintenance programs through a maintenance process that
begins by collecting data from sensors and historical data and
then displaying the solutions. Data analysis will then be shown
through statistical modeling and analysis techniques. Finally,
data and results are sent and displayed in control panels and
smart devices that provide employees with information to
make sound decisions about the state and maintenance of their
system.
Keywords: Predictive maintenance, Industrial Internet of
Things, Fault diagnosis, bearing.
I. INTRODUCTION
Since the 1950s, industrial machine manufacturers have
used data analytics to determine filers. However, the
collection, analysis, and use of these data to make
operational decisions take a significant amount of time.
Business intelligence tools were then implemented to
improve analysis and decision-making. Real value starts to
emerge as IIoT matures with machine learning and the
emergence of AI [1]. the Industrial Internet of Things, also
known as Industrial IoT or Industry 4.0, is an industrial
framework in which a huge number of devices or machines
are connected and synchronized using software and platform
technologies in devices -to- devices and Internet of Things
context. [2]. Maintenance that is more efficient for industrial
equipment saves a lot of money. It is a mix of extended
equipment life, more efficient field technician use, and
avoiding costly downtime, which can cause product delays
and pose safety risks. Many machine or equipment makers
want to deliver new services to their clients to generate new
3rd Dr. Shilpa Y. Sondkar
dept. Instrumentation Engg,
VIT College
India Pune, India
shilpa.sondkar@vit.edu
ac.in
revenue streams, and Industrial Internet of Things (IIoT)
technology can help them do so[3]. Machines on the
manufacturing floor or appliances in a customer's home can
even evaluate their performance and order their replacement
components when there are indicators that equipment needs
to be repaired when predictive maintenance is in place.
Predictive maintenance can even employ big data techniques
to forecast future equipment breakdowns. Predictive
maintenance is condition-based, meaning it only performs
maintenance when the component requires it. Industrial
maintenance, in particular, contributes significantly to this
competitiveness by ensuring the dependability and
availability of production equipment[4]. The maintenance
costs/added-value product ratio is considerably higher than
25% in continuous production businesses (for example, the
energy, chemical, food, cement, or paper sectors). Process
failures, it appears, can halt all production and have a
substantial impact on the manufacturing industry's
competitiveness. As a result, predictive maintenance has
become a crucial issue in recent years.
II. BACKGROUND
Sensors are considered one of the most main components
in mechanization and the new concept of industry 4.0 as they
monitor and evaluate the physical conditions of
equipment, to achieve the best control, reliability, and safety
of industrial equipment [5]. The point of predictive
maintenance is to upgrade systems that can generate precise
data probability forecasts, rather than just reporting them. An
automated system, for example, can control the entire
manufacturing unit of the organization. The system may
predict when a component will break and send a request to
the component in advance, allowing maintenance people to
replace it within a timeframe while maintaining the unit's
overall efficiency.
As a result, the outputs are extremely cost-effective[6].
The key element of PdM is Monitoring, in other words, PdM
can be considered condition-based Planner Maintenance [7].
Since maintenance costs make up a large proportion of the
cost of asset management, lowering these costs can represent
significant business savings [8]. Any device, machine,
electronic, or assembly that requires maintenance or that
improves performance or increases longevity after receiving
such maintenance is known as equipment. Any mechanical,
electrical, electronic, or optical equipment, and any software
related to mechanical, electrical, or electronic equipment, or
a data processing system, shall be considered as equipment.
Mechanical equipment refers to machines that include heavy
equipment and aircraft, automobiles, trains, transports,
hoists, heavy trucks, earth-moving equipment, or the like
[9]. Almost every aspect of modern manufacturing
operations benefits from the IIoT, including supply chain,
process control, logistics, maintenance, and infrastructure.
[10].
III. INDUSTRIAL INTERNET OF THINGS
The Internet of Things includes the Industrial Internet of
Things(IIoT). Large volumes of data are collected, collected,
and shared in a meaningful way on the Internet of Things. At
the local and commercial levels, the goal is to improve the
amount of automation. Data is especially important in the
industrial Internet of Things, which leads to a shift in human
tasks in the context of Industry 4.0, where automation
reduces certain forms of work while also necessitating new
capabilities[11]. The purpose of the IIoT is to improve and
safeguard human action rather than to entirely replace it.
IIOT incorporates machine learning(ML) and big data (BD)
technology, as well as SCADA (Supervisory Control and
Data Acquisition) technology and PLC (programmable logic
controller). So, also enhances automation technology by
incorporating self-diagnosis to make decisions and capability
of solutions. Physical devices (temperature, pressure, level,
vibration, flow, and many more) are used in in-process
control industries to gather data, but these data are now
employed in a new way for correction, analysis, and
exchange. [12]. IIoT devices are also frequently utilized to
ensure employee physical safety. Every year, many injuries
occur on factory floors and construction sites, some of which
are caused by malfunctioning machinery. Using the Internet
of Things to undertake the predictive maintenance mentioned
earlier will help reduce the amount of work-related injuries.
It can also be used to track worker adherence to safety
regulations, resulting in safer and more productive
workplaces [13].
IV. METHODOLOGY
Regardless of the application, the architecture for the
preventive maintenance model is pretty consistent. The
analyses are commonly found in several IT systems, with
layers being stated in the following order: Cloud or edge
systems for data capture and storage Convert raw data to
machine learning models through data transfer. Alerts
based on asset trigger restrictions, and status monitoring If
asset health deteriorates, diagnostic records based on trend
analysis are kept. Speculation - failure predictions based on
machine learning models, as well as estimation of
remaining life Recommendations for the Best Actions,
Decision Support System Information can be obtained in an
easy-to-understand format using the Human Interface Layer
[14]. The basic goal of PdM is to predict when equipment
may fail and to provide insights that aid in the machinery
maintenance planning process. Data is collected and
analyzed using Internet of Things technology - wireless
sensors to show real-time operation status [15]. The
predictive maintenance technique includes failure
prediction, fault diagnosis, failure type classification, and
recommendations for relevant maintenance operations [16].
The methodology is mainly composed of three steps, as
shown in Figure 1. In the first step, different data collection
from the industry field. Then, the second step is the
Analysis of data collected by models and forecasts. .
Afterward, the third step, is to display the results o f
data in the dashboard. The purpose of this work is to
allow the user to see the entire process from set point to
end. Predictive maintenance (PdM) approaches are aimed
to assist in determining the state of in-service machines so
that repair can be scheduled ahead of time. Data
acquisition, modeling and optimization, and presentation
are the steps in this method.
A. Data Acquisition
Data collection is the first and most crucial phase in
predictive maintenance, and there are two sorts of data:
sensor and test data. Sensor data is obtained from the
devices or system's sensors. The latest type of information
is a data test, in which data of sensor is acquired from a
test subject and used to prove and define data and sensor
models and connections. After collecting the data, you'll
need to process it before storing or analyzing it. Advanced
signal processing techniques will be used to process the
sensor data obtained. Advanced signal processing aids in
the extraction of sensor interactions [17]. Collecting
device data for predictive analyses often include
remote sensors. One of the side benefits of sensors is that
equipment can be checked without workers near it,
which is especially useful in dangerous locations. The
technician does not need to be exposed to unnecessary
risks [18]
B. Model and Optimize
Cost-benefit analysis, diagnosis and prognosis,
life projections, and failure mechanism and
impacts are only a few of the sorts of analyses that
can be done with the acquired data. The problem
to be solved must be defined before the analysis
can begin. The sort of analysis and data to be used
can be assigned once the problem has been
established. Based on the user's aims and
assumptions, the information can be utilized to
answer a variety of queries. Diagnostics and
prediction models can be constructed to display
information such as useful remaining life if the
user is absorbed in knowing the age of the
constituent or system he is monitoring [19].
Historical data will be used to construct a
prototype to detect the failure to create diagnostic
models and predictions. The current data is
compared to these models in real-time to
determine if there is a failure. Data from the
present is also saved and later utilized to improve
early error models. The outcomes of these models
must be interpreted once the data has been utilized
 Fig. 1. Methodology

to produce models and forecasts. Reports are greatest public uses of vibration Analysis, infrared images,
generated, work orders are generated, and and ultrasound signals show in Table 1.
maintenance activities are recommended as a Table 1: Common predictive technology applications.
result of this stage. Leadership, operators,

Equipment/Cran
Electric Motors
Applications ↓

Tanks, Piping
Transformers
maintainers, and engineers are examples of users

Condensers

Exchangers
Pumps

Valves
who might use these results to make decisions.

Heavy
Generators

Heat
Technol

es
ogy
Diesel

C. Present Vibration # # # # # # #
Monitoring/A
The final stage is to display the results of data in the nalysis
panel after finding the underlying cause of the problem Infrared # # # # # # # # #
and knowing the state of the equipment. These Thermograph
dashboards are tailored to the user's requirements, y
displaying only the data that is relevant to them. Users Lubricant, # # # # # #
Fuel Analysis
may see the sensor values on a graph on the screen,
Visual # # # # # # # # #
which can be used to predict when a failure will Inspection
happen. They can observe temperature, vibration, rpm,
and other important readings there. These panels permit
users to see real data in real-time, track trends, and keep Vibration can be used to detect mechanical defects in
an eye on system security. rotating equipment. Infrared is used to detect faults in
electrical circuits. Ultrasound is used to find leaks in
compressed air and gas lines [21].
V. PREDICTIVE MAINTENANCE EQUIPMENT & TESTING
TOOLS
Predictive maintenance uses non-destructive testing
A. Vibration Analysis
methods like infrared, vibration analysis, sound level
measures, oil analysis, and other particular online tests to Vibration analysis is conducted to identify the
assess equipment status [20]. Predictive maintenance operational and mechanical condition of the equipment.
software consists of vibration control, infrared imaging, and Vibration analysis provides several benefits, including the
visual examination. To maintain all the equipment, we potential to detect developing issues before they become
need a successful predictive maintenance program. It can
too serious and cause unscheduled downtime. Most
logically reduce costly downtime for machines by scheduling
maintenance only when needed. With the right tools, you can predictive maintenance solutions include vibration
predict when maintenance is needed. For example, the monitoring as a fundamental component. Vibration
monitoring can detect worn or broken gears, deteriorated or
damaged bearings, and mechanical looseness. Vibration
analysis can also reveal misalignment and unbalance before
they lead to shaft damage[22]. Vibration analyses are
particularly useful on high-speed rotating machinery, and
they can be the most costly part of a PdM program to
implement. The vibration's velocity, displacement, and
acceleration properties are assessed to define the severity of
the vibration, and these are generally referred to as the
vibration's " amplitude ".
1) Velocity (vibration velocity.)
2) Displacement (the degree to which the
measured component travels with each wave.)
3) Frequency (cycle of occurrence for vibrations).
Vibration amplitude (acceleration, displacement,
velocity ) is a measure of the severity of a machine's
problem, as previously stated. The determination of whether
the vibrations are acceptable to allow safe machine
operation is a common problem for vibration analysts.
These readings reveal the type of vibration that was
identified. The accuracy of the analysis ensures that the
correct scale or measurement is chosen.
B. Infrared thermography
One of the most crucial components in a successful
predictive maintenance program is infrared technology(IR).
This technique isn't simply for detecting anomalies in
electrical components and equipment caused by high
temperatures; it can also detect possible issues caused by
lower-than-normal temperatures [23]. The method of
employing a thermal imager to detect radiation (heat)
originating from an object, convert it to temperature, and
display an image of the temperature distribution is known as
infrared thermography. Thermograms are images of the
measured temperature distribution that allow you to see
heat-producing objects that aren't apparent to the human
eye. It's commonly utilized in condition monitoring and
predictive maintenance. Infrared thermography's major
objective is to validate that machinery is operating normally
and to detect anomalous heat patterns within a machine,
which indicate inefficiency and faults. For asset managers
tasked with predictive maintenance, adopting infrared
thermography to inspect mechanical equipment is a huge
benefit [24].
C. Oil Analysis
Approximately 80% of mechanical failures are due to
contamination, and oil analysis is one of the most simple
techniques to monitor contamination [25]. Another powerful
technology with numerous uses in several industries is oil
analysis. A sample of oil can be examined for viscosity,
wear particles, water content, and other factors. Oil analysis
is often used in industrial facilities to check essential
equipment such as compressors and gearboxes. Diesel
engine tests are regular and necessary in the transportation
business. Diesel engines generally work in harsh and
difficult operating conditions, such as train tracks, heavy
transport trucks, ships, and others. Oil analysis allows us to
precisely track the health of these engines in a way that
other predictive technologies may not be able to do in terms
of detecting bearing problems caused by metal particles or
chemical changes to the metal caused by high temperature,
and sealing problems caused by pumping fluids into the oil
[26].
D. Visual Inspections
A plant's machinery and systems must be visually
inspected regularly as part of any predictive maintenance
program. In many circumstances, a visual inspection will
reveal potential issues that other predictive maintenance
procedures will miss. Many potentially serious problems
can go undiscovered even with the prediction tools
outlined. Visual inspection of all essential plant systems
regularly will supplement the other procedures and
guarantee that any faults are identified before they cause
major damage[27]. IIoT Predictive Maintenance
accomplishes the same goal by analyzing massive amounts
of sensor data to see if the underlying gear is
malfunctioning. Root Cause Analysis (RCA) and Time to
Failure are provided based on this analysis.
VI. APPLICATIONS TO INDUSTRY
To develop the field of predictive maintenance, the IIoT
methodology can be leveraged to construct predictive
maintenance tools for Machines that produce large
quantities of data and require maintenance, and fixed or
fine-tuning of their parameters are found in all sectors.
Predictive maintenance may alter discrete sectors like
automotive, electronics, textiles, and aerospace, as well as
process industries like beverage and food, chemicals, gas &
Fig. 2. IIoT for PdM
 oil, and pharmaceuticals. Predictive maintenance can
address the issues that cause breakdowns and reduce the
amount of unplanned and needless maintenance.
Maintenance of general machinery, and oil & gas
components is expensive and growing, necessitating more
efficient maintenance techniques. Most predictive
maintenance may be performed while equipment is running
to minimize disturbance. Traditionally, the equipment has
been serviced on a time-based schedule, which has resulted
in wasteful maintenance reparations and a raise in
maintenance expenses. Because these sectors play such an
essential role in our lives, it is critical to developing their
maintenance procedures. Figure.2 shows three steps explain
using IoT for PdM The first is “data collection”, “model &
optimize” and then “present”. Show in the figure.3
1. Typical Machines
Pumps, Motors, fans, gearboxes, compressors,
conveyors, turbines, rollers, steel and paper industries,
engines, and machine tools with rotational parts are
examples of typical machines. The majority of these
industries are concerned with gear, bearing, shaft, and
chassis maintenance. Previously, these sectors used a time-
based preventive maintenance plan. As a result,
maintenance is one of the most significant cost drivers in
many businesses, accounting for up to 50% of overall
expenses. [28].
2. Oil and Gas Industry
Predictive maintenance solutions powered by IoT assist
gas and oil firms to foresee equipment faults before they
have a substantial impact on their safety and bottom lines.
The IIoT works to ensure that pipelines, crude oil
processing systems, and gas processing equipment are safe
and reliable. Sound variations that indicate fluid leakage
(such as crude oil) are detected using fiber-optic sensors,
Fig. 2. Healthy & Unhealthy of Bearing
temperature sensing systems, and ultrasonic sensors, while
hydrocarbon sensor cables are used to detect hydrocarbon
leaks. [29].
VII. DISCUSSION AND RESULTS
In this work, The Vishwakarma Institute of Technology
Lab has implemented the bearings for typical machinery to
apply Predictive Maintenance and monitoring for other
machines similar with just the component being monitored
changes. The bearing is fitted with sensors that collect
temperature and vibration data. almost in predictive
maintenance centers, special programs are employed to
process sensor data and store it in a database. The
MATLAB program was used to examine the signals and
images obtained in this study, and the data were processed
and analyzed. The data collected by the sensors is stored in
excel (.csv) spreadsheets for use in developing models and
applying machine learning algorithms. Figure.4 shows three
parts to explain what the users can see during this work. The
left of the figure presents the bearing signals that are normal
and abnormal for sensor readings. in the middle of the
figure, we see During bearing under normal operating
conditions nothing unusual is noted the photo is green and
there are no actions that need to be taken, and the bearing is
unhealthy show the device photo is the red color we should
do the measures to prevent failure.
In Figure.3, continuous monitoring of the thermal
behavior of the bearings under evaluation is performed by
capturing vibration signals and infrared images associated
with temperature values. When there is a thermal error we
will see that the temperature readings start to rise compared
to the time the bearing was operating normally. Through the
new data, fault models will now detect a thermal fault-based
it on which the necessary measures are taken directly.

VIII. CONCLUSION [9]
[10]
Anticipation is the basis of predictive maintenance to [11]
detect anomalies in equipment behavior to avoid many
problems and equipment failures in the future. Millions of
[12]
data and information are collected via sensors in real-time
and compared with historical data in the data canter. This
information is examined and used to forecast or infer what [13]
will occur at a specific moment. The predicted values are
then compared to the actual values, and the disparity
[14]
between them signals an uncommon event. The idea is to
spot malfunctioning machinery or deteriorating conditions
before they become a problem. The problem now is
determining how to interpret the outcomes of these [15]
inspections. Vibration, thermal imaging, ultrasound, oil
analysis, and motor circuit testing are some of the
techniques that can be employed. [16]
In today's competitive market, the combination of IoT,
smart devices, and cloud computing has offered the sector
the possibility to develop new maintenance tactics. By [17]
combining shared data, real-time monitoring, and data
analytics, the Internet of Things advances PdM's ability to [18]
empower businesses of all sizes to achieve optimal
performance and cost savings. As advances in technology
continue, so will the power of PdM and IoT diagnostics. [19]
Focus on developing PdM mainly for hardware and
software protection, equipment health tracking, and remote
[20]
monitoring
. [21]
[22]
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