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 .
Platform Economics | 16 May. 2018
AWS IoT Analytics is now ready
Amazon took over the AWS IoT Analytics service at the end of April 2018. It allows users to carry out a detailed evaluation of data from IoT...
Digital Twin | 01 May. 2018
Gas and oil rigs are getting digital safety support
Diamond Offshore Drilling has introduced the first digitally monitored blowout preventer. A digital twin mirrors seabed status in real time.
Platform Economics | 01 May. 2018
OpenServ4P shows online services for manufacturing
An open platform for predictive maintenance, quality assurance, and other smart services – that is the development goal of the joint...
Predictive Maintenance | 01 May. 2018
Compressor analytics optimize compressed air production
The Bielefeld-based company, BOGE, has developed a system for the constant overhaul of its machines. Customers benefit directly from...
Predictive Maintenance | 27 Apr. 2018
A retrofit kit makes machines fit for IIoT
Existing plants and older machines are also relatively easy to upgrade with modern predictive maintenance functions using retrofit packages.
Predictive Maintenance | 26 Apr. 2018
Analyze MyDrives monitors mechanical drive trains
Siemens is expanding its own MindApps for MindSphere with a machine monitoring program that enables the implementation of predictive drive...
Digital Factory | 24 Apr. 2018
Smart data measuring
ACNSENSA - the latest creation from aconno GmbH - is a highly efficient sensor beacon for capturing and storing environmental and physical...
Integrated Energy | 19 Apr. 2018
A communications solution that really WORXX
The SYS TEC stand at HANNOVER MESSE 2018 is hosting the new CTR-700 smart IoT gateway from the sysWORXX family - an edge controller for...
Startups | 17 Apr. 2018
Bearing up nicely
Sensosurf has a spot in the Young Tech Enterprises zone at HANNOVER MESSE 2018 to unveil its smart standard bearings. It is also showcasing...
Predictive Maintenance | 16 Apr. 2018
Why wait and see when you can be one step ahead?
The software developer Aspen Technology is at HANNOVER MESSE 2018 to showcase a comprehensive package of asset performance management...
Predictive Maintenance | 16 Apr. 2018
The Meta-Cloud combines individual solutions
Production processes usually use cloud solutions from several manufacturers. Taken individually, they are helpful in maintenance, but...
Predictive Maintenance | 14 Apr. 2018
Predictive maintenance secures power plants under partial load
The classic coal and natural gas power plants are not designed for the energy transition. The new flexibility also leads to new burdens on...
Integrated Automation, Motion & Drives | 11 Apr. 2018
Industry 4.0 in action!
On show at HANNOVER MESSE, the Smart Pneumatics Monitor from Aventics puts the theoretical advantages of Industry 4.0 into practice with...
Predictive Maintenance | 11 Apr. 2018
New cold-forming simulation accurately predicts cracks
Small cause, huge effect: In mass forming, pores (among other things) that could cause damage form in the component. Fraunhofer IWM has...
Digital Twin | 08 Apr. 2018
SAP introduces a cloud solution for digital twins
New software is to make physical inspections superfluous. SAP’s broadly digitalized system management aims to improve operating efficiency.
Digital Twin | 05 Apr. 2018
Kaeser digitally replicates its compressors
Compressed air specialist Kaeser is now working with digital twins. One the one hand, this enables predictive maintenance, while on the...
Predictive Maintenance | 04 Apr. 2018
Continental launches a remote monitoring tire platform
Together with Vodafone, Continental has launched the ContiConnect IoT platform. Companies can use it to monitor the condition of their...
Predictive Maintenance | 03 Apr. 2018
Optical sensors provide self-critical additional data
Balluff has developed two new sensors for the implementation of intelligent maintenance concepts. The all-round talents even send...
Research & Technology | 03 Apr. 2018
There's always room for improvement!
The AWS Institute has chosen HANNOVER MESSE to unveil 'predictive quality' - a brand new approach to quality assurance which uses artificial...
Predictive Maintenance | 31 Mar. 2018
In San Luis Potosí, Dürr is painting the BMW 3 Series
A fully automatic networked paint shop from Dürr is in use at the new BMW plant in Mexico, including an intelligent system monitoring unit.