Operators are now increasingly looking to retrofit classic machines with intelligent sensor systems including
data communication, thus creating the prerequisites for efficient condition monitoring. This requires – in
addition to the retrofitting of sensors – an efficient system for the sensor data transport from the machine to
a data processing and displaying system – without interfering with the actual machine control.
A large car parts
manufacturer in Portugal wanted to retrofit his several hundred machine tools – usually 12 per production line
accordingly. After a thorough market analysis, he commissioned the IIOT company IndustrialSYS, which had
proposed a powerful wireless solution using the Schildknecht CMS (Condition Monitoring System) in conjunction
with wireless PROFINET.
Retrofitting condition monitoring during ongoing production
The challenges of this project were the variety of machines (12 machines) – with or without sensors, with
analogue and/or digital signals, with different control systems – and the requirement to perform the CM retrofit
in a short time and without significant impairment of the ongoing production. All machines should be
upgraded to provide the following four operating parameters: The temperature inside the switch cabinets, the
cooling as well as the oil-hydraulic circuit temperature and the pressure of the hydraulic circuit.
All these parameters are important to extend the life of the machines, reduce downtime and thus increase
productivity.
In addition, the following
boundary conditions had to be fulfilled
- Process numerous analogue signals
- Bridge large distances between the machines in an "optimal" way
- Realise short installation and commissioning times
- Use a standard technology for easy integration into other applications
- Take into account that the machines cannot be networked with a local LAN
