Industrial IoT (IIoT) sensors are becoming increasingly widespread in Predictive Maintenance (PdM) for a variety of industry verticals. PdM is still largely manual and is dominated by vibration sensors (first created in the 1950’s), and a number of evolutions such as thermal sensors. The IIoT sensors in use today typically require mounting on each and every machine. Often, several dozen sensors need to be mounted on a single machine. The number of sensors compounds for larger, more complex and more critical machinery. Beyond the cost of hardware, which is usually no longer a major barrier, the sheer number of sensors required creates high overheads in implementation and sensor maintenance (tens of thousands of sensors per PdM project is not uncommon). PdM is thus currently resource-intensive. The IIoT sensors become increasingly difficult to implement and expensive to produce when dealing with hazardous or harsh environments that require specialised sensors to be deployed. Furthermore, they generally only measure single-point physical properties such as vibration or temperature which are often one-dimensional, inaccurate gauges for machine (or machine-component) state-of-health.
For the barriers to entry of PdM in IIoT to be substantially reduced, we would ideally need ‘sensing without sensors’. We would require a system that circumvents the current limitations with existing ‘IoT’ sensors and move towards fully-remote monitoring where a single device can be used to monitor multiple machines, at both a system and component level, even through walls. This is the type of system that has been devised and patented by leading researchers from Imperial College London: CogniSense is a remote condition-monitoring radio-frequency device. This technology can obtain more data than could ever be achieved with point-based sensors.
CogniSense has been validated in the laboratory (TRL 4), by measuring the motor speeds of household appliances with 100% accuracy, referenced with laser tachometers. We have strong reasons to believe that CogniSense can be a revolutionary step-change in condition monitoring and PdM to reduce the downtime of any mechanical machine. We are seeking vertically-integrated partnerships with IoT platform providers and/or domain-specific data analytics experts, to set-up field trials for validating the technology in industrial environments.
Priority application number: 1611894.5
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