Leveraging AI for Predictive Maintenance in Industrial Automation

Predictive maintenance has become a huge part of industrial automation, especially with the increase in automated machinery. There is a growing need for predictive maintenance in industries to reduce downtime, extend equipment life, and improve safety across the board. Within a smart manufacturing environment, AI tools can be a vital resource to stay ahead in your industry. MAISART, which is Mitsubishi Electric's AI State of the Art Technology, and compact built-in AI systems, are making a difference for customers. We will discuss how leveraging AI for predictive maintenance is transformative in the industrial automation industry and how we contribute to that.

The Power of Compact Artificial Intelligence

Compact AI is becoming a huge part of the industry, and it's an essential part of adding artificial intelligence to industrial automation. Compact AI is artificial intelligence that is integrated directly into hardware and controls of industrial machines, instead of through cloud computing, which is where AI is typically. Functional AI, or “boring AI,” typically outperforms the flashy type of artificial intelligence by solving operational challenges more efficiently, instead of just looking nice or seeming like they're adding to the efficiency. For industries that have strict safety, reliability, and real-time processing requirements, functional AI is typically the best option.

Mitsubishi Electric Technologies with Predictive Maintenance

It's no secret that predictive maintenance is becoming a huge part of industrial operations work, but ultimately, it is working hand in hand with AI to create new opportunities. Predictive maintenance technologies are built into many of our automation components. These have become a staple in our industry, and they have made a huge impact with the addition of artificial intelligence on machines. Take a look at some of our top technologies that have this feature:

• FR-E800 Variable Frequency Drives: These machines have AI-powered diagnostics built into the FR Configurator2 Software. The software helps predict failure trends based on error codes and predictive system behavior.
• MR-J5 Servo Systems: In these systems, AI is embedded in control algorithms and predicts mechanical failures, such as ball screw degradation and excessive friction.
• MELFA FR Series Robot Controllers: With MELFA Smart Plus enabling AI for predictive maintenance, grease and bearing life in robotic joints are monitored to reduce mechanical failures.
• GX Works3 PLC Software: This software has an AI Data Flow Analysis feature that identifies faulty logic paths rapidly and works between predictive and real-time diagnostics.
• ECOADVISOR Energy Monitoring: This uses AI to detect anomalies in power usage and also predicts whether machines are left running or if components of those machines are failing due to power consumption spikes.
• MELSOFT MaiLab Data Analytics Suite: This is an advanced statistical and machine learning suite that helps to support broader predictive maintenance use cases across varied machine types.

What Are the Benefits of AI-Driven Predictive Maintenance?

There are a lot of benefits to using artificial intelligence-driven predictive maintenance in the automation industry, especially when it comes to staying on top of potential problems and keeping machines operating efficiently. In machinery, there is little time for downtime, and having to do repairs or have emergency repairs done can set production back a lot further than you might think. Here is a look at some of the benefits of AI-driven predictive maintenance:

• Reduced Downtime: One of the biggest benefits of this type of maintenance is reduced downtime. Early detection of mechanical issues or wear and tears can help you fix these issues quickly.
• Lower Maintenance Costs: Shifting from reactive to proactive service schedules can help you be proactive in maintenance and stay ahead in fixing issues. Issues with machinery are a top reason why production could be pushed back, and additional manpower is needed in order to fix these issues or keep up with the fixes.
• Equipment Lifespan: Avoiding costly and worse problems through timely interventions maintains equipment lifespan. Keeping your equipment in good standing helps to ensure that there are no problems that will lower the life expectancy of your equipment.
• Optimization: Not having to do manual inspections helps to avoid extra manpower and pushes focus on other operations. You may not realize the amount of time it takes to inspect machines manually, but having this automated helps to keep the focus on operations, instead of inspections.

Conceptual Visions from Mitsubishi Electric

At Mitsubishi Electric, we are thinking of new ways to use generative artificial intelligence (GenAI) to further our impact and utilize new ways to push system design and support. With AI, there are many different ideas that can be used to help efficiency within the industry, and we hope to expand this with our offerings in the future.

Many in the industry are exploring generative AI ideas such as auto-generating robot code and PLC logic. Smart manuals and Q&A engines for rapid commissioning support are also ideas that would help give an instant and exact response to customer inquiries. These tools would help to reduce engineering time, improve accuracy, and support faster troubleshooting. Although these are not all predictive maintenance, they still will enhance the efficiency of automated systems.

Artificial Intelligence for Predictive Maintenance

Mitsubishi Electric is an industry leader when it comes to adding practical and predictive artificial intelligence directly into hardware and software, instead of cloud-computing devices. Through our initiative with MAISART, we deliver innovation, reliability, and efficiency. We work within the industry to provide a future of technology while using artificial intelligence as it becomes a more prominent part of our future, especially in automation technology. Although there are both “fun” AI and “boring” AI, there is a use for both of these when it comes to mechanics. Predictive maintenance is a big part of this industry, and we hope to implement more of that in the future of Mitsubishi Electric. Predictive maintenance powered by AI isn't uncommon; it's a new modern necessity for industrial performance and keeping up with efficiency in the industry.

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