IIoT Success Story

GraceSense™ Predictive Maintenance technology was recently deployed at a Fiat Chrysler Stamping Plant in Warren, Michigan. Like many automotive stamping plants, this facility encompasses millions of square feet and houses more than a dozen stamping lines. These lines usually operate 20 shifts per week and produce parts that are shipped to numerous other facilities across the United States and around the world.

During an initial pilot at the Warren Stamping Plant, the GraceSense™ Predictive Maintenance System captured nearly 28 million data points over a 24-month period. In that time, a swift return on investment was realized as the system provided alerts that prevented eight downtime incidents, saving FCA over $2M in losses; almost fifteen times the cost of the entire GraceSense™ project.

Continuous Temperature Monitoring

GraceSense™ Hot Spot Monitor (HSM) Identifies faults before they occur and saves money by preventing unplanned outages, service interruptions, and equipment failures. Design and communication flexibility allows the HSM to be used as either stand-alone or fully integrated into a plant wide information system.  Plant wide integration is made simple when the device is connected via MODBUS TCP I/P or Ethernet I/P to the facility’s SCADA/ DCS systems while stand-alone application is made possible with GraceSense™ web interface to configure temperature thresholds, monitoring intervals and relay outputs.

Temperature monitoring is critical for every industry and application that demands system reliability and high uptime. While HSM is ideal for every industry application, our primary targets are the industries that currently implement thermography programs, have older equipment, and lack resources to perform routine maintenance tasks. 

Potential Failure Points (PFPs) vary by customer preferences including load conditions, incident energy, environment and criticality of the equipment. They frequently occur due to loose connections.

NFPA 70B, Chapter 17.9 Loose Connections:

"Excessive heat in a circuit breaker can cause a malfunction in the form of nuisance tripping and possibly an eventual failure. Loose connections are the most common cause of excessive heat. Periodic maintenance checks should involve checking for loose connections or evidence of overheating..."

Grace Engineered Products, Inc

1515 E. Kimberly Road
Davenport, IA 52807

T: 563.386.9596
F: 563.386.9639
Toll Free: 800.280.9517

Email: sales@grace-eng.com