Design & Implementation of Automatic Machine Condition Monitoring and Maintenance System in Limited Resource Situations

In the era of the fourth industrial revolution, it is essential to automate fault detection and diagnosis of machineries so that a warning system can be developed that will help to take an appropriate action before any catastrophic damage. Some machines health monitoring systems are used globally but they are expensive and need trained personnel to operate and analyse. Predictive maintenance and occupational health and safety culture are not available due to inadequate infrastructure, lack of skilled manpower, financial crisis, and others in developing countries. Starting from developing a cost-effective DAS for collecting fault data in this study, the effect of limited data and resources has been investigated while automating the process. To solve this problem, A feature engineering and data reduction method has been developed combining the concepts from wavelets, differential calculus, and signal processing. Finally, for automating the whole process, all the necessary theoretical and practical considerations to develop a predictive model have been proposed. The DAS successfully collected the required data from the machine that is 89% accurate compared to the professional manual monitoring system. SVM and NN were proposed for the prediction purpose because of their high predicting accuracy greater than 95% during training and 100% during testing the new samples. In this study, the combination of the simple algorithm with a rule-based system instead of a data-intensive system turned out to be hybridization by validating with collected data. The outcome of this research can be instantly applied to small and medium-sized industries for finding other issues and developing accordingly. As one of the foundational studies in automatic FDD, the findings and procedure of this study can lead others to extend, generalize, or add other dimensions to FDD automation.