IIOT Gas Anomaly Detection System for Daikin
Real-time monitoring solution using nRF52, MQTT, Power BI, and AWS for predictive maintenance
Industrial IoT Gas Monitoring Platform
Pyzen Technologies developed a comprehensive IIOT solution for Daikin to monitor gas anomalies in their manufacturing facilities. This system leverages nRF52 microcontrollers for sensor data collection, MQTT for real-time communication, AWS for cloud processing, and Power BI for advanced visualization and reporting.
The solution enables Daikin to detect gas leaks and anomalies in real-time, preventing potential hazards, reducing downtime, and optimizing maintenance schedules. By implementing predictive maintenance capabilities, Daikin has significantly improved operational safety while reducing costs associated with unplanned equipment failures.
Our system processes thousands of data points per second from sensors deployed across Daikin's manufacturing facilities, providing actionable insights through an intuitive dashboard that can be accessed from any device.
The Industrial Safety Challenge
Daikin, a global leader in air conditioning solutions, faced significant challenges in their manufacturing facilities:
• Gas Leak Detection: Traditional systems had slow response times and high false positive rates
• Predictive Maintenance: Lack of real-time data made it difficult to predict equipment failures
• Multi-location Monitoring: Needed a centralized system for multiple manufacturing facilities
• Regulatory Compliance: Strict safety regulations required comprehensive monitoring and reporting
• Cost Efficiency: Manual monitoring processes were labor-intensive and expensive
The company needed a scalable, reliable solution that could provide real-time insights while integrating with their existing infrastructure.
Our IIOT Technical Solution
We designed and implemented a comprehensive IIOT ecosystem tailored to Daikin's specific requirements:
nRF52 Microcontrollers: Low-power wireless sensors deployed throughout facilities to monitor gas levels, temperature, and pressure.
MQTT Protocol: Lightweight messaging protocol for efficient real-time data transmission from edge devices to the cloud.
AWS IoT Core: Secure cloud platform for device management, data processing, and storage.
AWS Lambda & Kinesis: Serverless computing and data streaming for real-time anomaly detection.
Power BI Dashboards: Comprehensive visualization tools for operational insights and regulatory reporting.
Mobile Alerts: Instant notifications to facility managers when anomalies are detected.
Real-time Monitoring
Continuous tracking of gas levels across all facilities
Predictive Analytics
AI-powered algorithms to predict potential failures
Instant Alerts
Immediate notifications for critical anomalies
Cloud Integration
Seamless AWS cloud connectivity for data processing
Mobile Access
Remote monitoring capabilities from any device
Historical Analysis
Comprehensive reporting for trend analysis
Technical Architecture
The solution was built with a robust, scalable architecture designed for industrial environments:
System Architecture
Edge Layer (nRF52)
Low-power microcontrollers with gas sensors for data collection
Communication (MQTT)
Lightweight protocol for efficient data transmission
Cloud Gateway (AWS IoT Core)
Secure device management and data ingestion
Processing (AWS Lambda)
Serverless functions for real-time anomaly detection
Storage (AWS Timestream)
Time-series database for sensor data storage
Visualization (Power BI)
Dashboards for operational insights and reporting
Technology Stack
Measurable Business Impact
The implementation delivered significant operational and safety improvements for Daikin:
Detection Accuracy
Highly accurate anomaly detection with minimal false positives
Response Time
Near real-time alerting for critical conditions
Maintenance Cost Reduction
Predictive maintenance reduced unexpected downtime
Regulatory Compliance
Comprehensive reporting for safety regulations
Implementation for Daikin Manufacturing
Challenge
Inefficient gas monitoring leading to safety concerns and high maintenance costs
Solution
IIOT system with real-time monitoring and predictive analytics
Outcomes
- Zero safety incidents since implementation
- 45% reduction in maintenance costs
- Real-time monitoring across 5 manufacturing facilities
- Automated compliance reporting
Implementation Process
Requirement Analysis
Comprehensive assessment of Daikin's facilities and safety requirements
Sensor Deployment
Strategic placement of nRF52 sensors throughout manufacturing facilities
Cloud Architecture
Design and implementation of AWS IoT infrastructure
Dashboard Development
Creation of Power BI dashboards for visualization and reporting
Testing & Deployment
Rigorous testing and phased rollout across all facilities
Client Feedback
Pyzen's IIOT solution has transformed our safety monitoring capabilities. The real-time alerts have prevented potential incidents, and the predictive maintenance features have significantly reduced our downtime.
James Watanabe
Operations Director, Daikin
The integration of nRF52 sensors with AWS and Power BI has given us unprecedented visibility into our manufacturing processes. We can now identify and address issues before they become problems.
Sarah Chen
Safety Officer, Daikin
Frequently Asked Questions
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