The Estimation of the Remaining Useful Life of Ceramic Plates Used in Iron Ore Filtration Through a Reliability Model and Machine Learning Methods Applied to Industrial Process Variables of a Pims

The intensive use of various sensors in industrial machines has the potential to indicate the real-time health status of critical equipment. This is achieved through the connectivity of their automation systems (PIMS and MES), enabling the optimization of the preventive maintenance interval, a reduction in corrective maintenance and safety-related failures, an increase in productivity and reliability and a reduction in maintenance costs. Through the use of the CRISP-DM data analysis methodology, the fault logs of ceramic plates applied in an iron ore filtration process are coupled with sensor readings of the process variables over the time of operation to create exponential survival models via two techniques: a multiple linear regression model with averaged data and a random forest regression machine learning model with individual instant data. The instantaneous reliability of ceramic plates is then used in the online prediction of the remaining useful life of the components. The model obtained from the instantaneous reading of 12 sensors led to the estimation of the remaining useful life for ceramic plates with up to 5600 h of use, allowing the adoption of a strategy of replacing these components by condition instead of replacing them by a fixed time, leading to increased process reliability and improved stock planning. The linear regression model for reliability prediction had an R2 of 78.32%, whereas the random forest regression model had an R2 of 63.7%. The final model for predicting the remaining useful life had an R2 of 99.6%.