In the old days, a production plant had to break down before it could be repaired. Today‘s intelligent systems recognise faults before they appear. Predictive Maintenance can make enormous cost-savings and open the way to new business models.show more
Advance maintenance full-steam ahead
Repairing machines before they break down – that is what predictive maintenance can do. Integrated machine monitoring is what you need to do it.
The topic of predictive maintenance has become increasingly important in recent years, and is inseparable from the themes of Industry 4.0, the Internet of Things and Big Data. Technology manufacturers are equipping machines and industrial systems with sensors that enable remote monitoring when combined with the right software. To what end?
Repair before downtime occurs
This approach is based on servicing and maintenance, which is no great novelty in and of itself. For years, many manufacturers have been earning more money with aftersales service than with the mere sale of their machines. But unlike in the past, predictive maintenance does not commit operators – whether of printers, aircraft, CNC mills or automobiles – to set maintenance schedules. Because regular or sporadic maintenance has a fundamental drawback: Users all utilize their machines differently, which makes wear difficult to calculate.
Predictive maintenance enables the permanent monitoring of components inside the machine – using sensors that measure vibration, temperature or humidity, for example. Specialized maintenance software collects this sensor data, evaluates it and recognizes in advance when a component might be in danger of failing. Defective components that could soon lead to a system shutdown are identified independently of the usual maintenance schedule, and can be replaced before damage actually occurs.
Predictive maintenance brings big cost savings
The key advantage of predictive maintenance comes down to two words: cost effectiveness. This is technology that limits downtimes, saves energy and reduces maintenance costs. The potential savings are enormous. The US rail company Union Pacific reports savings of some USD 100 million annually through predictive maintenance. Reason enough for Deutsche Bahn to launch its own innovation project in the area of servicing and maintenance. And these days, predictive maintenance makes sense for more than just the big machines and systems. Software and sensors are ever more efficient. ABB presented a solution for low voltage engines at HANNOVER MESSE 2016 , for example, which is relatively affordable and is quickly amortized even at smaller scales.
Machine maintenance is well on the way to entering a new era. Instead of reacting when a component no longer works, technicians in the future will act before a defect becomes apparent and causes costly downtime. And not only that, but continuous data analysis gives users of smart machines a much more precise picture of their facilities: Operating errors or wrong settings become a thing of the past in this scenario, or can be rapidly recognized and corrected. In the best cases, predictive maintenance analyzes not only data from the machine itself, but also influencing factors such as order frequency, material quality or even the weather.
Predictive maintenance thus moves into predictive producing – and a production unit becomes a veritable smart factory.
Discover the innovations heading for the market at HANNOVER MESSE. Learn how to deploy cutting-edge machine maintenance in your company. Visit the Predictive Maintenance display .
Digital Twin | 16 Oct. 2018
Innogy and Shell invest in digital twins
The investment arms of energy groups Innogy and Shell are backing IT startup Akselos, a digital twin specialist, with US$ 10 million...
Predictive Maintenance | 08 Oct. 2018
EMAG strengthens its digitization competence
The machine designer EMAG is taking over a minority holding in the data analysis specialists anacision. As a result, the company intends to...
Digital Twin | 06 Oct. 2018
Digital twin monitors unmanned drilling rigs
Kongsberg Digital has presented a model for remote monitoring of offshore platforms. The system will make it possible to search for oil and...
Predictive Maintenance | 21 Sep. 2018
Flying laser system enhances wine
The scientists at the German Aerospace Center are developing a flying laser system that detects fungal infestation of grape vines at an...
Predictive Maintenance | 18 Sep. 2018
Predictive maintenance should work for entire plants
A new system combines predictive maintenance with machine learning and expert knowledge, with the aim of preventing false alarms.
Industrie 4.0 | 17 Sep. 2018
Munich Re acquires IoT startup Relayr
Munich Re wants to leverage Relayr’s software developments to generate more accurate risk analyses. The startup offers end-to-end IoT...
Industrie 4.0 | 07 Sep. 2018
The analysis tool for industrial plants fits into a suitcase
A mobile sensor system developed by the Fraunhofer Institute in Lemgo is particularly suited to medium-sized companies. No bigger than a...
Predictive Maintenance | 07 Sep. 2018
Smart sensors send timely warning about bridge damage
Düsseldorf Airport monitors a critical bridge thanks to numerous sensors. The data is exchanged via the Internet of Things.
Predictive Maintenance | 29 Aug. 2018
Continental is checking air springs with ultrasound
The automobile industry supplier has developed a sensor for air springs, which should make city buses, in particular, safer and more...
Research & Technology | 23 Aug. 2018
Fraunhofer Institute and Omicron conduct research on photocatalysis
The Fraunhofer Institute for Surface Engineering and Thin Films (IST) and Omicron have developed a novel measuring gun. It makes it easier...
Predictive Maintenance | 13 Aug. 2018
Simply collecting data is not enough
If it is possible to develop a new service culture based on the data for predictive maintenance, the global market for it could grow by as...
Integrated Automation, Motion & Drives | 24 Jul. 2018
Virtual gearbox sensors calculate the next oil change
The risk calculation is simple: the bigger the industrial gearbox, the heavier the drive technology – and the greater the forces that can...
Predictive Maintenance | 24 Jul. 2018
Matlab has made new advances in AI and sensor data
The latest innovations of Matlab include the Predictive Maintenance Toolbox and direct access to Nvidia GPUs.
Predictive Maintenance | 21 Jul. 2018
Structure-borne sound sensors give maintenance alarm
The vibration data of a machine allow surprisingly accurate conclusions about its level of wear. Intelligent algorithms will recognize...
Predictive Maintenance | 19 Jul. 2018
Decentralized fieldbus system finds faults more quickly
A diagnostic gateway from Murrelektronik allows access to sensor data without additional programming work. This helps it locate the sources...
Research & Technology | 14 Jul. 2018
Galileo Online helps the railway with autonomous shunting
Autonomous driving is of interest not only to the auto industry. RWTH Aachen University, in collaboration with project partners, has...
Cobots | 04 Jul. 2018
Yaskawa Cockpit evaluates process data in real time
Yaskawa is expanding its own offer in the area of Industry 4.0 with the software platform Cockpit. It allows the real-time monitoring of...
Predictive Maintenance | 02 Jul. 2018
Ultrasound can hear microorganisms growing in pipes
Predictive maintenance requires a constant flow of data from all relevant points. A clever retrofit solution for water pipes was invented at...
Digital Factory | 01 Jul. 2018
Sick enters the system business
Sick has reorganized its e-card production at the Reute location as a smart model factory. At the same time, the sensor specialist is...
Digital Twin | 29 Jun. 2018
Maintenance planning for long-distance trains is done using a digital
To better plan maintenance, Laing O'Rourke uses digital twins. According to the conference report, the railway company save a great deal of...