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WORLD OF INDUSTRIES - MDA 2/2017

WORLD OF INDUSTRIES - MDA 2/2017

Full-service package for

Full-service package for complete peace of mind Compressed air is a vital energy source for industrial applications. Without it, production grinds to a halt. Predictive maintenance is important for spotting potential problems at an early stage. This helps to reduce or entirely eliminate unexpected downtime and the resulting production backlogs. The result: improved productivity, product quality and planning security, and lower maintenance and service costs. Author: Daniela Koehler, Press Officer, Kaeser Kompressoren SE Repairing machines only when they break down: that’s how things used to be done, even with compressed air systems. Today, modern control technologies such as the Sigma Air Manager 4.0 (SAM 4.0), combined with intelligent data analysis, make it possible to plan ahead when scheduling the maintenance of the compressed air supply system. With digital networking and the networking of machines with each other and with a service centre, operators and manufacturers can track and analyse the status of machine components on a continuous basis in order to predict optimal maintenance times. This “predictive maintenance” concept helps to detect impending faults, speed up processes and prevent production downtimes. Predictive maintenance is nothing new for Kaeser. For more than 30 years the company has offered operator models under which customers purchase only the compressed air volumes that they actually use. Kaeser retains ownership of the compressed air station (contracting model) and takes care of everything else. To minimise costs and maximise availability, Kaeser has been developing and implementing machine-integrated master control systems and teleservice solutions for many years. But it is only now, with the WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 2/2017

02 Real-time data monitoring is performed in the service centre availability of modern databases and enormous improvements in sensor technology, that real-time monitoring and predictive maintenance have become a reality. Tailor-made solutions Customer needs vary widely. Kaeser has a diverse range of service packages geared to specific requirements. One model, the Sigma Air Utility, is based on the existing contracting models, which leave nothing for the customer to take care of. Kaeser assumes full responsibility. Similar to the electricity or water supply, customers pay only for the compressed air that they use. This leaves them with more liquid assets on hand for their core business activities. Another model, Sigma Smart Air, is designed for customers who own their compressed air stations. As regards service and availability, however, they are just as care-free as those who opt for a contracting solution – because Kaeser handles everything. According to Kaeser’s estimates and the initial experiences, this model can save up to 30 percent in service costs for customers. Whether the compressed air station is owned by the customer or Kaeser, the basic requirement for using predictive maintenance is the Sigma Air Manager 4.0. This core control technology was developed by Kaeser – as were the analysis tools behind it. The master control system itself is the core element of a compressed air station and is essential for utilising everything Industry 4.0 has to offer. It functions as a central brain for the controlling tasks and data streaming to the data (service) centre, which performs continual monitoring and analysis. When potential faults are detected, a process is initiated to ensure the problem never reaches the point where components stop functioning. Along with fault analysis, the control system determines when maintenance is actually needed, as opposed to following a fixed schedule. This switch to needsbased maintenance also saves costs. 01 The Sigma Air Manager 4.0 (SAM 4.0) master controller functions as a management system for the compressed air components and as a central node for secure data exchanges Infrastructure, expertise and intelligent services are essential A system operator planning to introduce predictive maintenance will need an excellent compressed air system infrastructure like that provided by the Sigma Network. Real-time monitoring is possible only if the system components are equipped with sensors that enable the master control system to monitor activity, retrieve data, and transfer it instantly. Naturally the vast quantities of raw, unfiltered data are of little use on their own. Appropriate analysis processes must be developed to extract useful information and predict events. This requires human input – just like the steps that follow. The global service network needs to be just as extensive and effective as the data network to ensure a prompt and cost-effective response when action is needed. The right combination of infrastructure, expertise and intelligent services is essential for exploiting the full benefits of predictive maintenance. www.kaeser.com The cornerstone: knowledge and experience Essential for the development of such predictive maintenance concepts is the extensive knowledge, accumulated over many years, on the processes, interrelationships, vulnerabilities and challenges involved in producing and using compressed air. It is this knowledge on the part of Kaeser’s specialists – combined with the latest technologies – that makes it possible to rapidly analyse and evaluate the status of a station and to promptly initiate any steps that may be needed. WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 2/2017