Self diagnosis, self-learning, self-control! Instaguard device intelligent monitoring and diagnostic system makes enterprise device monitoring easier!

In the era of Industry 4.0, especially for process industries, the normal operation and risk avoidance ability of equipment are key indicators of production and operation. Intelligent monitoring of equipment has become the core of improving enterprise production efficiency and reducing operation and maintenance costs.

However, in the traditional field of equipment maintenance, we mainly see a model dominated by "post repair" and "preventive maintenance". With the rise and application of cutting-edge technologies such as big data, artificial intelligence, the Internet of Things, and digital twins, the revolutionary new model of "predictive maintenance" is rapidly emerging and challenging traditional concepts. Predictive maintenance provides enterprises with a more advanced and proactive way to safeguard machine health.
Today, we are honored to introduce to you the innovative work from SINGYE - the Instaguard Device Intelligent Care Diagnostic System (referred to as the "Instaguard System"). As a pioneer in the field of industrial PHM, SINOGYE has created this fully independent intellectual property industrial intelligence APP with self diagnosis, self-learning, and self-control, relying on fully automated artificial intelligence AI technology.

-Product Overview

The Instaguard system is a powerful PHM application system that can monitor the health status of devices in real-time, reduce unplanned downtime losses, and enhance the equipment care and analysis capabilities of enterprises.
At present, the Instaguard system is widely used in multiple industries such as petroleum, petrochemicals, steel, electricity, coal, pharmaceutical printing, etc. It has accumulated over 2000 monitoring devices and its algorithm accuracy can reach 85%, making enterprise equipment care unprecedentedly simple.

-Product Architecture

As shown in the figure, the Instaguard system is composed of iComputer, intelligent IOT hardware, application components, and visualization pages, and can support various network scenarios such as privatization and public cloud.

1. iComputer

In the privatization scenario, iComputer, with its powerful automation control capabilities and dual domain operating system, completes process data collection, intelligent IOT hardware data reception, artificial intelligence AI algorithm inference and operation, and data storage. At the same time, by utilizing the edge algorithms embedded in the intelligent IoT hardware and communicating with the Instaguard system deployed on iComputer, edge cloud collaboration is achieved, rapid response is made, greatly reducing server and control hardware costs, and lowering the difficulty of data collection.

Currently, the Instaguard system supports SX21 series iComputers and SP series iComputers. The SX21 series iComputer can support up to 80 machine status monitoring diagnostic instruments and 1000 IOT point synchronous acquisition, AI analysis, and store 4-year historical data; The SP70 series iComputer can support up to 130 machine status monitoring diagnostic instruments and 2000 IOT point synchronous acquisition, AI analysis, and store 4 years of historical data.

2. Intelligent IoT hardware

Intelligent IoT hardware includes wireless communication machine status monitoring and diagnostic instruments, machine status data receivers, and wired data collectors.

01 Wireless Communication Machine Status Monitoring and Diagnostic Instrument

• Data collection: Collecting acceleration, velocity, and temperature data of the device with high accuracy, with a frequency response range of up to 0.1Hz to 10000Hz, and monitoring temperature from -40 degrees to+120 degrees;
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• Acquisition type: not only speed, acceleration waveform and installation position temperature can be acquired, but also speed and acceleration characteristics can be extracted through the built-in edge computing algorithm, and the running status and fault condition of rotating equipment can be early warned and predicted;
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• Communication method: using Zigbee or 4G Cat1 communication method, no wiring or network deployment required;
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• Installation and deployment: Supports various installation and deployment methods such as screws, magnetic suction, and adhesive, and is equipped with a large capacity detachable and replaceable battery. While meeting the 2-year long service life, it is convenient for users to replace it later and extend its service life. The diagnostic instrument has an IP67 protection level and is certified for intrinsic safety and explosion-proof.

02 Machine Status Data Receiver

• Supports up to 90 Ziebee diagnostic instrument connections, with a maximum communication distance of over 150 meters;
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• The dual processing architecture can effectively perform edge computing and data processing;
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• Equipped with IP68 protection level and explosion-proof certification, it can be flexibly used according to on-site needs.

03 Wired Connection Data Collector

• Adopting a 24 bit ADC acquisition, it can support simultaneous 8-channel, 16 channel, or 24 channel IEPE acceleration full synchronous sampling, with a sampling rate of up to 102.4K;
• The collector also has explosion-proof certification.

3.Application components

The Instaguard system provides IotHub components for configuration and Metafact components for algorithm flow processing, supporting full cycle management of application hardware, data cleaning and processing, configuration configuration, and custom management of AI algorithm models.

These functions help customers optimize the unit algorithm, improve algorithm accuracy, and achieve precise monitoring of equipment.

4.Visualization page

The Instaguard system provides visual displays to users in the form of web pages.

In the system, customers can view the real-time operation dashboard of the unit, intuitively understand the current operating status, health level, and AI predicted operating condition position of the unit. On the details page, customers can clearly view the real-time status, recent operation, health level distribution, latest real-time data, and historical warning information of the current unit. The details also provide full lifecycle management functions such as customized uploading of unit diagnostic reports and unit data management.

In addition, the system also provides rich graph visualization diagnostic functions, which cover the graph views needed by diagnostic analysts in the market. Utilize the interactive large model and knowledge graph developed by Zhongke Era for operation and maintenance knowledge training, root cause analysis of faults, and maintenance knowledge.

-Product Highlights

1. Visual display, evidence-based decision-making

The Instaguard system provides visual displays in the form of web pages, allowing customers to intuitively view real-time operation dashboards, health levels, AI predicted operating condition locations, and other information of the unit. On the details page, customers can clearly understand the real-time status, historical data, warning information, and diagnostic reports of the unit, providing strong support for decision-making.

2. Intelligent linkage, fast response

When device abnormalities are detected, the Instaguard system can automatically issue an AI fault diagnosis report and notify customers through various methods such as SMS, email, and system pop ups. At the same time, the system is linked to the iComputer control domain PID to issue real-time device adjustment instructions, helping customers quickly adjust processes and reduce unplanned downtime losses.

3. Open integration, seamless integration

The Instaguard system has good openness, and through the various integration methods provided by Fastkit components (Restful API, MQTT, OPC UA, RabbitMQ, iframe page integration, etc.), users can quickly complete system integration work and reduce additional costs.

The Instaguard device intelligent monitoring and diagnosis system not only enables real-time monitoring and accurate diagnosis of devices, but also improves the operational efficiency of enterprises and reduces operating costs through intelligent management.

We believe that through the use of Instaguard, you will be able to easily tackle various challenges in the industrial field, making equipment care simpler and more efficient.