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Case Study

With Predictive Maintenance, you can monitor the condition of your equipment and make decisions based on those conditions

AA Electric developed Vibe-Sight to make Predictive Maintenance easy. Their goal with Vibe-Sight is to do all of the hard work of gathering the data and analyzing it to determine the health of your system and that is why they chose a Maple Systems headless HMI as part of this solution. Vibe-Sight, paired with our HDMI-enabled headless HMI, helps monitor vibration and temperature, its changing conditions, and displays important information.

AA Electric

Industry: Automation & Control
Location: Multiple Locations, USA

Case Study: AA Electronics' Vibe Sight

Project Scope

When AA Electric set out to develop Vibe-Sight, a Predictive Maintenance Solution, they had 7 main goals:

  1. Provide "True" Predictive Analytics:
  2. Many of AA Electric's competitors offer predictive solutions without providing predictive analytics. These offerings required the user to analyze the data. AA Electric's main goal was to provide a true predictive analytics solution that did not require third party fixes, cloud interfaces, or interpretation of graphs and charts to make decisions.

  3. Easy to install:
  4. Vibe-Sight uses Banner Engineering’s vibration and temperature sensors and radios. Allowing you to install sensors in minutes.

  5. Out-of-the-box, ready to run, solution:
  6. Many of AA Electric's competitors require the use of wizards to set up devices, effectively giving you a pick from the list solution. This totally ignored the fact that, like fingerprints, all machines are unique. AA Electric chose to make Vibe-Sight a fully automated system. First, finding a true running state , then analytically determining the proper warning and critical alarm set points. It's truly easy to set up with close to no downtime or engineering required.

  7. Provide real-time monitoring:
  8. To be truly effective, a predictive maintenance solutions need to be seen 24-7, without an operator having to log in to see what’s going on. That’s why AA Electric created a 'live GUI' for Vibe-Sight that can be displayed on a large screen tv or monitor allowing real-time monitoring of your plant’s devices. Up to 47 devices can be displayed at one time.

  9. Email Alarms:
  10. Because you can’t always be looking to see if problems occur, AA Electric added email alarming to let you know about predictive alarms as they occur. In addition, they added a cybersecure interface to allow remote access.

  11. IIoT Ready:
  12. Not everyone wants a stand-alone system. That’s why AA Electric provided a ModbusTCP Gateway to bring all pertinent data out to the “edge” to allow SCADA or MES System access. Additionally, their solution takes advantage of the 300 different connection protocols supported in EBPro. And for those users that want to send data to the cloud, a Maple System HMI supports MQTT, Sparkplug B, OPC UA, and SQL integration.

  13. Scalable:
  14. Finally, one size does not fit all. We developed Vibe-Sight and Vibe-Sight Lite on an open architecture platform which allows easy modification for special needs. In addition, AA Electric has an Integrator / OEM program that allows companies to make special customized solutions to meet their needs!

The Solution

AA Electric did a very exhaustive search and selected a Maple Systems HDMI-enabled headless HMI for their analytics engine. AA Electric chose our HMI because it provided an HDMI port for visualization, a web based GUI functionality, and the ability to use SQL, Java Script, OPC-UA, and MQTT. Plus the cMT Viewer feature included in our free configuration software, provided a free, lite client viewer for remote viewing of the application. And finally, our our HMI was cost effective.

Requirements our headless HDMI-enabled HMI met:

  1. High Speed
  2. Open Architecture for programming
  3. Easy to Obtain programming software
  4. A high level of on-board memory for variables
  5. An easy-to-use programming structure
  6. On-Board Data Logging
  7. On-Board Realtime and Historical Trend Charting
  8. The ability to Trend Historically over a full year
  9. On-Board visualization
  10. Ability to display the Visualization GUI on a Widescreen TV or Monitor
  11. Ability to allow at least 5 simultaneous remote viewers access into the GUI
  12. And lastly it had to be cost effective

Predictive Health Indicator

Using machine analytics and high-level statistics, Predictive Health Indicator “Health Halo” provides an indication of the health or failing health of a system or device.

Our Value Promise

Long renowned in the Industrial Automation industry for the quality of technical support we have provided for decades, Maple Systems has a reputation for connecting customers with someone who knows our products inside and out. Whether it is one of our trusted System Integrator partners, Distributors, or our own engineering team, we are happy to connect you with a knowledgeable engineer dedicated to understanding your application.

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Supported Products

HDMI-Enabled HMI
HDMI-Enabled HMIs

This HDMI®-enabled unit works with screens of any size, making screen size no longer a limitation in your application. As part of our HMI series, it has all the rich functionality found in our HMI series without a the touchscreen display. Monitor PLC operations, gather data, and remotely access your control system via the cMT Viewer App on your Apple/Android smart phone, or your own tablet/laptop/PC.

Learn more about our HDMI-Enabled HMIs