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Detect anomalies for increased machine availability

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IoT Use Case - BLUE-ZONE
5 minutes Reading time
5 minutes Reading time

The digital monitoring of machines ensures precise recording and analysis of condition data. This enables early detection of anomalies, reduces downtimes and optimizes maintenance processes. Modern IoT technologies and a flexible software solution make processes more efficient.

The challenge: Optimizing digital maintenance for machines

A special machine manufacturer produces specialized rotary transfer machines that produce workpieces with high quality and efficiency. A major challenge for them and their customers in the automotive industry is the maintenance of these machines. It requires planned shutdowns and a coordinated approach. The machine manufacturer has founded its own service company for this purpose. The employees check the machines on site, assess the condition of the spindles and replace them if necessary.

The service technicians follow fixed maintenance schedules. However, testing involves a great deal of manual effort, which is why the special machine manufacturer thought about a digital solution. It is designed to collect important basic data in the spindles and automatically transfer it to an application. The company wants to use it to create a modern maintenance solution that makes the entire maintenance process more efficient. The aim is for the service technicians to know where faults have occurred and which components need to be replaced before they are deployed to the customer.

The special machine manufacturer has partnered with BLUE-ZONE GmbH to develop the software and select the necessary hardware. The company from Hagenberg in Upper Austria has more than 20 years of experience in end-to-end automation. It helps its customers to digitalize and automate internal and external processes. The company offers both standard solutions and customized solutions.

The solution: Detecting anomalies and avoiding unplanned downtime

With its software solution for digital monitoring and analysis of machines, BLUE-ZONE enables precise and continuous monitoring of machines and components – such as spindles in rotary transfer machines. At the heart of the solution is real-time data collection through the use of modern IoT technologies.

Data acquisition with a wide range of sensors

After installing sensors on critical machine components, numerous parameters can be monitored. These include, for example, the spindle speed, current consumption, temperature, torque, feed speed and the exact XYZ position of the spindle. This data forms the basis for precise condition monitoring of the machine and enables a detailed analysis of the machine’s behavior.

The solution was developed in close cooperation with the machine manufacturer’s specialist departments so that it can be seamlessly integrated into existing processes. Therefore, no fundamental restructuring is necessary for their implementation. Instead, companies can build on existing processes and optimize them.

Detecting anomalies and avoiding faults

The sensor data reaches the Internet via a gateway and is transferred from there either to the user’s in-house data center or to the customer’s preferred cloud platform, on which the BLUE-ZONE solution is based. This flexibility allows users to choose the infrastructure that is best for them. Regardless of location, users have access to a clear dashboard on which the collected information is visualized. Here they can track the condition of the machines in real time and detect deviations immediately.

The BLUE-ZONE solution makes it possible to detect anomalies at an early stage and take timely action before costly breakdowns occur. This significantly reduces unplanned downtimes. This leads to higher machine availability on the one hand and optimized maintenance cycles on the other. Instead of being serviced at fixed intervals, the machines are serviced as required – saving time and money. Altogether, this improves the overall equipment effectiveness (OEE).

Valuable data for product development

The continuous monitoring of the machines also provides valuable data for product development. By evaluating the machine data, weak points in the design are uncovered and information is provided on how to improve machines and processes. This means, for example, that future machines will be more efficient, more durable and easier to maintain. The refeeding of data back into the development process is therefore a further added value of the BLUE-ZONE solution.

Another advantage is the option of automatic software updates. These keep the software up to date without manual intervention by the user. The updates offer security-relevant changes and functional enhancements that are developed based on the analysis of machine data. Users benefit continuously from improved algorithms for error detection and extended functions for optimizing machine performance.

The result: Machine data as the basis for innovations

By collecting data using IoT technologies, the BLUE-ZONE solution continuously monitors machine conditions and detects anomalies at an early stage. The software reduces downtimes, optimizes maintenance cycles and improves machine performance (OEE). Further features will be added to these basic functions in the near future.

A first step in development is the remote configuration of machines. This allows users to adjust machine parameters and machine functions remotely. This has particular advantages in global production networks, as machines at different locations can be configured centrally.

Another development goal is integration into existing ERP systems so that machine and process data flows directly into planning and production and business processes are more closely interlinked.

Predictive maintenance is a key focus of further development. It uses data-based predictions to determine when maintenance is required and thus detects signs of wear on components at an early stage.

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