Protecting critical infrastructure in every industry
PRECOG predicts the failure of any complex machine driven by an electric motor, to prevent downtime and unplanned maintenance and to ensure business continuity. It can build on existing measurement infrastructure and provides its own sensors where needed.
Strategic value
What operators and stakeholders gain
Risk mitigation
PRECOG reduces the risk of sudden, costly breakdowns by finding problems before they escalate.
Operational efficiency
Predictive insight supports data-driven decisions, reduces emergency repair costs and improves the lifetime of the assets.
Brand protection
Reliable infrastructure helps to uphold the standards that customers and guests expect.
Sustainability and ESG
Early fault detection leads to more efficient energy use and less waste, which supports sustainability targets and reduces the environmental impact.
Hotels and buildings
PRECOG for hotels, offices, hospitals and shopping centres
PRECOG ensures continuous building operation by predicting failures about two weeks in advance for the whole complex infrastructure, whether it consists of critical or non-critical motors.
- Elevators and escalators
- Water pumps
- Heating and ventilation systems
- Air conditioning systems
- Fire pumps
- Sewage and drainage pumps
- Backup generators
Critical motors are essential for safety, infrastructure and uninterrupted operation.
- Kitchen appliances
- Laundry equipment
- Automatic doors
- Pool and spa pumps
- Smart blinds and curtains
- Cleaning robots and vacuums
Non-critical motors are still important, but their failure does not threaten the overall operation of the building.
The quality of a hotel is often judged by its design, service and comfort, yet much of its function runs silently behind the scenes, powered by critical and non-critical motors. They operate everything from air conditioning to elevators and from kitchen equipment to wastewater systems. Counting the critical and non-critical motors is the starting point for working out how many measuring devices a building needs.
Critical building infrastructure
Pumps, air conditioning, refrigeration and lifts
PRECOG ensures continuous operation by predicting failures about two weeks in advance for high-power water and air pumps, AC units, refrigeration units, elevators and escalators, and any other equipment driven by an electric motor.
- Drive motors and traction units
- Gearboxes, brakes and counterweight systems
- Control electronics and safety modules
- Door operators, sensors and communication systems
- Ventilation and cooling components
PRECOG analyses power, current, temperature, vibration, position and other physical factors.
- Water and wastewater pumps
- Booster sets and circulation pumps
- Motors, impellers and bearings
- Variable frequency drives and control electronics
- Cooling fans, seals and coupling units
PRECOG analyses power, current, temperature, vibration, pressure, flow and other physical factors.
- Air compressors and cooling pumps
- HVAC units
- Conveyor and lifting equipment
- Power distribution and control panels
One monitoring approach for the whole technical infrastructure of a building.
PRECOG ensures maximum uptime, energy efficiency and passenger safety across lifts, pumping systems and building infrastructure.
Railways and public transport
Turnouts, doors, barriers and vehicles
| Rail vehicle system | What PRECOG monitors |
|---|---|
| Brake systems | Wear of brake pads and discs, overheating and abnormal vibration |
| Compressed air supply units | Leakage rates and air pressure stability, compressor vibration and efficiency, moisture or filter contamination |
| Doors and coupling systems | Wear of actuators and motors, early detection of electrical and positioning failures |
Manufacturing
Robots, conveyors, presses, machining and utilities
PRECOG ensures continuous operation by predicting failures about two weeks in advance for welding robots, paint line infrastructure, conveyor belts, press machines and any other equipment driven by an electric motor. The tables show typical equipment, the measured factors and the faults that can be detected.
Assembly, paint and material handling
| Equipment | Measured | Detected |
|---|---|---|
| Robotic arms (welding, assembly, handling) | Power, vibration, current | Motor fatigue, joint misalignment, gearbox wear |
| Conveyor belts and transfer units | Power, vibration | Belt wear, roller misalignment, drive motor degradation |
| Torque tools | Torque, current | Calibration drift, mechanical stress |
| Press and stamping machines | Vibration, pressure, temperature | Misalignment, abnormal force, lubrication failure |
| CNC and machining centres | Vibration, temperature, power | Spindle or bearing wear, tool imbalance |
| Paint line infrastructure (booths, mixers, ovens) | Power, temperature | Fan fatigue, heater degradation, uneven heating |
| Spray nozzles and filtration units | Pressure, flow, power | Clogging, reduced spray quality, filter blockage |
| Forklifts and lift systems | Power, temperature | Overheating, hydraulic issues |
| Conveyors and elevators (internal transport) | Power, vibration | Drive or belt fatigue, tension anomalies |
Machining, welding, repair and positioning equipment
| Equipment | Measured | Detected |
|---|---|---|
| CNC lathes, main spindle units | Vibration | Bearing wear, component wear, imbalance, prediction of manufacturing anomalies and prevention of machining inaccuracies |
| Machining and repair stations for critical components | Vibration, power, current, temperature | Spindle or bearing wear, tool imbalance, drive degradation |
| Welding cells, rotating and positioning equipment | Current, power, vibration, position | Motor fatigue, shaft or gearbox wear, positioning error |
| Composite and honeycomb repair cells | Temperature, power, vibration, position | Heat profile deviation, motion anomaly, fan or drive wear |
| Motorised measurement and inspection stations | Position, vibration, current, temperature | Actuator failure, calibration drift, loss of repeatability |
Material handling, hydraulics and safety equipment
| Equipment | Measured | Detected |
|---|---|---|
| Roller conveyors | Power, vibration, temperature | Bearing fatigue, motor overheating, brake wear, misalignment |
| Positioning actuators | Power, position, vibration, torque | Gear wear, encoder drift, shock load fatigue |
| Hydraulic units | Pressure, vibration, power, temperature | Seal leakage, pump wear, cavitation, actuator failure |
| Cooling fans | Power, vibration, temperature | Fan bearing wear, overheating, dust accumulation |
| Buffer units and stopper actuators | Power, vibration, position | Cushion wear, spring fatigue, malfunction, jamming |
| Access gates | Power, vibration | Motor and gear wear |
| Emergency stops | Power, temperature | Contact fatigue, control unit degradation |
| Optical and load sensors | Power, temperature, position | Electronics degradation, calibration drift, structural strain |
Utilities and plant infrastructure
| Equipment | Measured | Detected |
|---|---|---|
| Air compressors, vacuum pumps | Power, temperature, pressure, vibration | Overheating, leakage, bearing or seal wear |
| HVAC systems and cooling towers | Power, vibration, temperature, airflow | Fan imbalance, filter clogging, pump wear, motor fatigue |
| Ventilation and exhaust fans | Power, temperature | Degradation, imbalance |
Food and drink production
Raw material handling with belt, roller and chain conveyors, bucket elevators and palletisers. Mixing and processing with agitators, dosing and metering pumps, homogenisers and pasteurisers with circulation pumps. Filling and packaging lines with filling, capping, labelling, wrapping and case-packing machines. Automated storage and retrieval systems, product lifts and access gates. Utilities such as water pumps for supply, cleaning in place and cooling, compressors, refrigeration units, cooling towers and fire suppression pumps. Motor-driven sampling systems for quality control.
Data centres and telecoms
Cooling, power and IT indicators
Mechanical systems
- Server room cooling fans and CRAC systems, with speed fluctuation and signs of lost cooling
- Cooling motors of UPS and inverter modules, with bearing fatigue and overheating trends
- Cooling motors of communication and monitoring stations, with fan fatigue and rising vibration
IT and network indicators
- Network, operations and failure KPIs predicted before an outage
- Hardware reliability, for example through physical clock signals on circuit boards
See the telecommunication case study.
Airports and logistics
Passenger, baggage, security and airside equipment
| Area | Equipment |
|---|---|
| Passenger transportation | Elevators, escalators and moving walkways |
| Baggage handling | Conveyor belts, automated sorting systems with motor-driven diverters, lifts and arms |
| Security and operations | Sliding doors, revolving doors, access gates, fire and smoke extraction fans and pumps |
| Airside and ground infrastructure | Hangar and taxiway gates, passenger boarding bridges, motorised runway and taxiway lighting |
| Power and climate control | HVAC fans, compressors and pumps, diesel generator starter motors and fuel pumps |
The same approach applies to logistics centres: conveyor motors and belts, automated lifts and hoists that suffer overload fatigue, and the cooling and HVAC equipment of the building.
Energy, water and process industries
Pumps, compressors, fans and process equipment
Oil, gas and process plants
| Area | Equipment and detected faults |
|---|---|
| Raw material handling and transport | Crude oil pumps (seal wear), pipeline compressors (bearing wear), loading pumps (motor fatigue) |
| Refining process equipment | Distillation pumps (shaft misalignment), heat exchangers (fouling), furnace blowers (fan fatigue), catalyst dosing pumps (cavitation) |
| Utilities and plant infrastructure | Cooling towers (pump wear), steam boilers (feed pump failure), air compressors (overheating, leaks), refrigeration units (compressor wear) |
| Material movement and storage | Tank valves (wear), conveyors and elevators (belt fatigue), access gates (motor failure) |
| Quality control and safety | Sampling units (actuator failure), ventilation fans (motor degradation), firewater pumps (seal wear) |
| Upstream systems | Hot oil pumps, cooling water circulation pumps, soft water and layer water pumps, firewater pumps and gasoil pumps. Measured: vibration, load, pressure-holding cycles and start frequency. Detected: bearing wear, shaft misalignment, seal leakage, overheating and fire-risk patterns |
Electricity grid substations
| Equipment | Detected |
|---|---|
| Transformer oil cooling fans and pumps | Bearing wear, temperature anomaly, reduced output |
| GIS compressors, valve actuators of SF6 and air systems | Signs of seal and pressure loss, rising friction, position deviation |
| Motor drives of breakers and switches | Rising torque, mechanical play |
| Ventilation and air conditioning motors | Load swings, overheating |
| Motorised gates and door drives | Gear wear, starting current peaks |
| Firewater pumps, smoke extraction and pressurisation fans | Seal wear, motor current anomaly |
Is your industry missing from the list? Any machine driven by an electric motor can be a candidate.