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Get the Power of Predictive Maintenance

8/29/2025

The benefits of predictive maintenance are clear—reducing machine downtime, enabling maintenance to be scheduled when it will least disrupt operations and keeping overall costs down. The thing that may not be so obvious is the best way to implement predictive maintenance. Not all facilities have the time or manpower to incorporate new systems into existing processes and equipment. Rockwell Automation’s FactoryTalk® Analytics™ GuardianAI™ leverages existing PowerFlex® drives (755, 755T and 6000T VFDs) as the data source for condition-based monitoring of pumps, fans and blower applications. With this software, OT teams have access to the power of applied analytics and machine learning, without the need to understand evolving data science or introduce new sensors. GuardianAI learns the normal operations of your assets and automatically notifies you of any deviation.

Analytics in 4 Steps

  1. Initial setup- Deploy the application an edge device or virtual image, connect your VFD by entering the drive’s IP address, then specify which asset to monitor.
  2. Training/modeling- Establish a baseline in the software for each asset’s behavior by inputting parameters of normal operation for that particular asset.
  3. Monitoring- GuardianAI continually monitors the health of the asset. Users can access health summaries to plan downtime and increase plant safety.
  4. Notifications- When the software detects any deviation is asset performance, users receive a warning email that includes identification of what the fault is (bearing fault, stator fault, broken-bar, misalignment and application-related faults). Investigation and resolution follow. These alerts can be integrated with CMMS systems for work order generation and maintenance planning.

Benefits

  • Real-time results at a fast pace
  • Streamline troubleshooting and maintenance scheduling
  • Leverage existing resources (no data science or extra sensors required)
  • Give maintenance engineers knowledge of the parts needed for repairs
  • Reduce time offline
  • Increase production and cost savings

Questions or Requests

For help integrating FactoryTalk Analytics GuardianAI with your PowerFlex drives, contact your McNaughton-McKay account manager or visit your local branch today.

Additional Resources