IIoT for predictive maintenance


Heidenhain has introduced its Advanced Diagnostic System (ADS), which provides built-in encoder condition monitoring.

Encoders placed on the motor, drive shaft or other rotating or moving components in the machine monitor parts that are crucial for smooth and reliable production-line performance. Condition monitoring data and system diagnostics from the encoder can reveal motor performance and the state of installations while in operation. Data can be collected and analysed in terms of vibration, temperature variations, frequencies and time in motion at all encoder installations.

ADS solutions will simplify the move from preventative to predictive maintenance. This helps companies to practice proactive maintenance, since encoder data lets them adjust factors that would otherwise reduce machine life. Correct motor installation avoids unnecessary problems, which significantly reduces production downtime. A single prevented production stop covers the cost of all ADS encoders at the plant.

The tool allows manufacturers to set alarms for any value and analyse graphs to compare deviations or changes and react to them. With ADS encoders, manufacturers can take four types of maintenance approach before or during production:
  • Corrective: replacement at breakdown;
  • Preventative: replacement according to schedule;
  • Predictive: replacement at incipient fault (condition-based maintenance); and
  • Proactive: analysis and adjustment to extend the time for change.

The Industrial Internet of Things (IIoT) needs to be built from the component level up. With encoders, the undisputed function is process control, but the devices can also provide data to systems and networks on different organisational levels. OPC Unified Architecture (UA), a machine-to-machine communication protocol, enables two-way communication so that the encoder can deliver data and respond to inquiries and needs from within the systems when prompted.

A greater amount of information from process-critical components results in better control of plant operations. The encoder can:
  • Store and deliver detailed operational data, which is accessible through various computer systems;
  • Give ordering systems access to serial numbers in time for replacement; and
  • Provide time-in-motion data for performance trends of running applications.

The next generation of the ADS is available for wireless service check-up via Bluetooth, system integration via OPC UA or both. The wireless service check-up facilitates maintenance and drive system management, production planning and operation. Users can perform service check-ups on the go via the mobile app.

Users can keep cables from current encoder installations and switch to an ADS Uptime encoder by adding an ADS Link module in the control cabinet. The new encoder can now connect to systems on other levels of the organisation via OPC UA.

System functions include condition monitoring, resource planning, supervisory control and data acquisition (SCADA) and maintenance management.

OPC UA is a platform-independent industrial communication protocol that exchanges data between products from different manufacturers and addresses operating systems.

Real-time data and warnings can be a part of systems at all levels in the company.