THE CHALLENGE
Our customer operates a custom-built, analog 30t punch-bending machine whose control process must not be interfered with. Small hairline cracks in the large drive wheel can lead to machine failure, resulting in a production stop. Due to high storage costs, the spare part is not kept in stock. However, order and delivery times for the replacement part can take up to three weeks. In order to avoid machine downtimes, the machine is to be digitally linked to the current production environment, while condition monitoring is to analyse the condition of the drive wheel and predict future breakage in useful time.
The aim of our client was to use a digital retrofit to make his machine IoT-ready to be able to reduce machine downtimes and increase machine uptimes.OUR SOLUTION
It was indispensable to digitally activate the existing plant, so the client first installed sensors to detect gear breakage. The solution used, Fraunhofer IPT ‘s vBox, processes the sensor signals and sends the data to compacer’s data platform edbic.
The system now measures structure-borne sound, vibration, temperature, torque, current and other data. The system detects, for example, an increased power consumption , which can be a sign of an increased load caused by friction and lack of lubricant. However, the collected and evaluated data can also alert operators of fissures and cracks.
The frequency spectrum and other values are recorded and analysed for outliers in real-time. If an outlier is detected, for example a value indicating a crack, the system logs and alarm and alerts an operator. The staff can then act accordingly and avoid a production standstill.