Enhancing Industrial Machinery Monitoring with Data & AI: ISE Contribution to evocation

ISE is proud to contribute to the pioneering EVOCATION project within the BI-REX Consortium providing its maintenance and predictive maintenance services. With its extensive experience in developing and deploying custom acquisition systems, ISE plays a crucial role in the project, enabling data collection from smart sensors and making them accessible to all partners.

Each smart sensor deployed by our partners comes with its own unique requirements, making connectivity a complex and challenging task. Our adaptable Twise^® solutions are specifically designed to address these challenges, providing the necessary flexibility to ensure seamless integration with each unique use case. ISE’s solution ensures that critical data is captured accurately and efficiently, enabling all partners to access invaluable insights in their manufacturing processes.

In addition to data collection, ISE provides essential support for the initial analysis of raw data.  This assistance allows our academic partners to focus on interpreting the data and developing advanced AI-based analytics methods. Together, we are advancing the field of predictive maintenance and smart manufacturing.

The project’s mission is to expand the current monitoring capabilities for industrial machinery, unlocking new scenarios for how manufacturing companies approach maintenance and quality.

The EVOCATION project is financed by the European Union – Next Generation EU.

The EVOCATION Project

EVOCATION, a joint initiative promoted by BI-REX Consortium, focuses on leveraging cutting-edge technology to provide smarter and more detailed machinery monitoring. By integrating new smart sensors and advanced computational capabilities powered by AI, we aim to predict and prevent even rare failures.

Innovative Sensors and Collaborative Excellence

EVOCATION aims to introduce a cost-effective way to monitor diagnostic parameters and load conditions of machinery, by leveraging smart sensors and advanced data analytics.

In collaboration with four manufacturing industries and five more technical service providers we’re creating a synergy of hardware and software excellence to step up remote monitoring and smart maintenance for industrial machinery and plants.

Overcoming Complexities

Monitoring specialized machinery presents unique challenges. Some critical physical quantities are notoriously difficult to measure while machines are operating. Deformations, loading, and lubricant conditions serve as close predictors of failures, but obtaining precise near real-time data might require costly sensors, and in some cases no sensors are currently available at all.

Additionally, specific failure incidents occur rarely, making data scarce. Reproducing these incidents in controlled environments involves expensive processes. Furthermore, real-life systems defy complete top-down mathematical descriptions. Unpredictability is inherent, necessitating adaptive approaches for maintenance planning and repairs.

The Synergy of Hardware and Software

EVOCATION’s solution lies in the synergy of hardware and software. Advanced AI-driven real-time calculations complement direct measurements from innovative smart sensors.

Implementing our vision involves addressing several critical challenges. Smart sensors require a digital interface and embedded computational capabilities. Data needs to be collected stored and managed on an adequate software architecture. Data analytics, customized for specific indicators, must be meticulously constructed and optimized for each use case.

Artificial Intelligence is used to fill gaps where traditional top-down models fall short, providing fine-grained data predictions in a digital twin kind of approach. Hybrid methods, including Physics Informed Machine Learning, enhance AI’s capabilities. By combining black-box AI with the interpretability of mathematical modeling, we aim to create a comprehensive set of measurements. These measurements empower accurate predictions related to maintenance planning and machinery life expectancy.

A Vision for the Future

In the scenario envisioned by EVOCATION, the entire plant can be monitored with renewed detail, and decisions can be simulated using what-if scenarios, enabling proactive adjustments and informed choices.

Partners

EVOCATION’s greatest strength lies in the specialized competencies, domain knowledge, and extensive experience of our partner members.

Manufacturing partners, global leaders in their respective fields, provide tangible examples for solution development and real-life testing:

• Bonfiglioli: A leading producer of gear motors, drive systems, planetary gearboxes, inverters, and electric motors across Industrial, Automation, Mobile Machinery, and Wind Energy sectors.
• Poggipolini: Innovators in weight reduction, critical components, and structural fastening systems for Aerospace, Automotive, and Motorsports sectors.
• SACMI: Manufacturers of machinery and plants for Ceramics, Plastics, Food & Beverage, Metals, Packaging, and Advanced Materials sectors.
• Velan ABV: Experts in industrial steel valves for applications such as Power Generation, Chemicals, and Cryogenics services.

Technical partners, driven by innovation, contribute to designing advanced components and interactions for our envisioned solutions:

• E.S.T.E.: Specializing in hardware, firmware, and software design, including complex signal management. E.S.T.E. will contribute to the development of a smart sensor.
• Sanchip: Focused on predictive maintenance through advanced IoT devices for plants and machinery. Sanchip will contribute to the development of a smart sensor.
• Sens-In: A Poggipolini spin-off, specializing in smart fastening elements. Sens-In will provide hardware, setup, and data interpretation support.
• BitBang: A Data & AI consultancy with a tailored approach, specializing in Big Data, Data Analytics, and Data Science. BitBang will take care of the software architecture and data management.
• Selcom Group: Experts in customized electronic and electromechanical equipment and systems. Selcom Group will contribute to the development of a smart sensor.
• ISE: Providing maintenance and predictive maintenance services. ISE will contribute to the development of smart sensors, and to the acquisition and first analysis of raw data.

Academic partners contribute essential research, forming the bedrock of our project’s decisions:

• CIRI ICT: The University of Bologna’s Interdepartmental Industrial Research Center, focused digion ICT technologies. CIRI ICT will focus on developing AI-based and hybrid data analytics methods.

MechLav Laboratory: The Industrial Research Laboratory of Ferrara’s Technopole. MechLav Laboratory will focus on optimizing data extraction and interpretation from sensors.