Proactive maintenance (proactive TO) is a method of maintaining the operability of a vehicle fleet by monitoring parameters and identifying signs of malfunctions.This allows for repairs and replacement of consumables at the right time.
This approach is an alternative to planned maintenance, which is carried out according to a schedule, ignoring the actual condition of the equipment. Proactive maintenance focuses on the real need for repair, ensuring uninterrupted operation of equipment and reducing costs.
Preventative maintenance is most effective for modern, complex machines operating in harsh conditions where fuel consumption and wear on the engine or other components are difficult to control.
These machines include mining and quarrying equipment, construction equipment, specialized oil and gas production machines, rail transport, watercraft, and diesel generator sets and power plants.
Considering the high costs of complex equipment and maintenance, reaching 50% of fleet expenses, the implementation of 24/7 remote diagnostics and predictive maintenance allows for a significant reduction in costs due to the following advantages:
- Reducing risks of equipment downtime due to unexpected breakdowns
- Increasing service life of machinery through careful operation
- Optimizing maintenance rapidity – technical team is prepared for work in advance
- Improving fuel economy – e.g. fuel consumption does not increase due to wear of fuel filters
- Saving on spare parts replacement -part whose resource has not been developed are not serviced
Predictive maintenance is based on accurate data on the operation of equipment (machines and vehicles). The more parameters are monitored, the more complete the picture of the fleet's operation.
Sensors and control units are used to measure parameters. Technoton devices determine more than 10,000 parameters, transmitting data for GPS tracking and analysis.
Stages of predictive maintenance implementation
Compiling a list of important parameters for equipment, the change of which requires maintenance.
Types of additional devices, counters, input/output modules and gateways, as well as data available from the main vehicle equipment.
A search for patterns – i.e. typical behavior of parameters during normal operation and in a pre-emergency state, identification of a responsible person and a response procedure.
In-field works by telematics system technicians, installation and commissioning, telematics device testing, fleet personnel training for using telematics system.
Before predictive maintenance, the telematics system needs to collect data. It is analyzed manually or using machine learning. Specialists service the equipment.
Engine and fuel system
Several important groups of parameters
Fuel monitoring – instant fuel rate (also called hourly fuel consumption), total fuel used and split by operating modes. Fuel volume in tank and fuel temperature.
Temperature and pressure of engine oil and coolant. Indicates the condition of technical fluids, filters and other consumables
Engine RPM. If RPM alters within the same operation mode, then this may indicate problems with engine or violation of machinery operation rules.
Suspension and braking system
Health (wear) of brake pads and other elements of brake system.
Malfunctions of ABS, EPS, ECAS and other electronics assistance systems
Axle load.
Onboard electrical equipment
On-board network voltage.
Battery voltage, current and temperature.
Technoton specializes in the development and production of a wide range of sensors, flow meters, readers and CAN i/o modules for monitoring the operating parameters of modern machines.
Given the complexity of modern systems with multiple control points, Technoton has implemented S6 technology - a wired interface based on CAN J1939/71. This technology allows receiving data from more than 100 on-board devices via a single wired bus connected to one port of the telematics gateway.
