IDM-Online rotating equipment condition monitoring system with analytics module based on generative AI

IDM is an industrial diagnostic system that combines traditional vibration diagnostics methods with generative artificial intelligence. The core of the solution is the analysis of the vibration characteristics of operating equipment using specialized sensors.

The uniqueness of the approach lies in the use of generative AI for deep analysis of the received data. The AI analyzes the vibration diagnostic data, compares it with predefined threshold values and fault patterns, and identifies deviations from the norm at an early stage.

When anomalies are detected, the AI generates a detailed report in natural language, describing the identified deviations and their possible causes. Based on the data analysis, the system provides maintenance recommendations, including timelines and work priorities.

The technical implementation includes hardware components (vibration acceleration sensors and data collection systems), a cloud platform for storing and processing information, and an AI module for analytics.

The use of generative AI makes the results of vibration diagnostics more accessible for understanding by enterprise personnel, allowing for timely decisions regarding equipment maintenance and the prevention of emergency situations.

Neural LLM network for vibration prediction based on historical data.
Generative AI for analyzing vibration diagnostic data, identifying anomalies and deviations, generating reports, and providing maintenance recommendations.

Pilot project

Mining industry
Metallurgical industry
Cement production
Machine building
Oil and gas industry
Main pipelines

We develop and implement a system for monitoring the condition of rotating equipment, which helps avoid losses due to sudden breakdowns.
In the 24th year, we conducted 8 pilot tests and helped to avoid 9 serious breakdowns.
Based on the results of pilot tests, we plan to implement more than 20 systems in 2025.

In 2024, through early detection of faults and timely recommendations to avoid breakdowns, we helped avoid more than $3 million in losses
Our customers are businesses that operate high capacity equipment.
The problem is that all this equipment doesn't just break down, it breaks down suddenly. I.e. the equipment looks serviceable, but the fault has already started and is developing. The existing automated control systems cannot detect them, but only state the breakdowns.
Half of production stoppages are caused by sudden equipment failures. And production stoppage means lost profit.

IDM stands out from other solutions in the vibration diagnostics market with two key features:

1. Application of generative AI
Analyzing vibration diagnostics data with Claude Sonnet
Generating easy-to-understand natural language reports
Generating clear maintenance recommendations
Explain complex technical data in simple language
Quickly analyze large data sets

2. Affordability of technology
3-5 times lower cost of the basic solution compared to analogs
Clear reports do not require deep knowledge in vibration diagnostics
Possibility of gradual expansion of the system
Quick start of use

While competitors focus on providing technical data requiring interpretation by specialists, our solution makes vibration diagnostics available to a wider range of enterprises and specialists. This is especially important when there is a shortage of qualified vibration diagnosticians.
The combination of affordable pricing with generative AI capabilities creates a unique value proposition in the industrial diagnostics market.

Development of AI capabilities:

Expanding the functionality of generative AI for comprehensive technical data analysis.
Implementing a multimodal approach (parallel operation of multiple AI models).
Developing a specialized module for aligning results from different AI models.
Creating an industry knowledge base for industrial equipment.
Scaling AI services:

Launching AI as a Service for remote diagnostics.
Developing an online platform for expert support based on AI.
Implementing an API for integration with existing monitoring systems.
Technology development:

Improving algorithms for vibration data analysis.
Expanding the range of diagnosable faults.
Enhancing the accuracy of failure predictions for equipment.
Focusing on the development of AI components will create a unique technological advantage and ensure leadership in the field of intelligent industrial diagnostics.

As part of promoting the rotating equipment condition monitoring system IDM-Online, clients are offered the opportunity to test the system as part of pilot industrial trials on a gratuitous basis.
Pilot industrial trials have been conducted at the facilities of the following clients:

TOO “EuroChem Karatau”
TOO “KZ Recycling”
TOO “Bakrichik Mining Enterprise”
TOO “Araltuz”
AO “Altyn Almas”
Pilot industrial trials have been completed at the facilities of the following clients:

TOO “Kazminerals Aktogay”
AO “FIK Alel”
AO “Qarmet”
Pilot industrial trials are planned at the facilities of the following client:

TOO “Eurasian Group”