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Predictive Maintenance ? Recognise today what will not work tomorrow

Predictive maintenance as a business model in the digitalisation of mobile machines

optiMEAS Predictive Maintenance

The increasing digitalisation of industrial processes also requires adaptation at management level in the form of marketable, data-based business models in order to create the greatest possible added value.

The technical possibilities for networking the elements involved in the 'IoT' are diverse and far from exhausted. Profitable predictive maintenance is the common goal of manufacturers, rental companies, suppliers, customers and service partners. But how does Big Data become Smart Data?

From telematics to predictive maintenance

Process optimisation begins with the use of data in further processing into information. The more facts are available, the more informed a decision can be made. For the mobile machinery sector, internet-based telematics and teleservice solutions enable remote diagnosis and maintenance of machines in use. The analysis of real operating and usage data can also help to improve products in machine development.

The progress of digitalisation now makes it possible to monitor entire processes and even include external data (e.g. weather or traffic). Conventional telematics solutions are no longer sufficient here. It is necessary to intelligently connect measurement and control technology. In this context, smart data means the continuous collection and evaluation of the combination of many different real-time and historical data in order to recognise patterns, derive trends and finally make predictions.

Smart data management can be used to make statements about the quality, fatigue and determination of the service life of individual components. On the one hand, this results in automated diagnoses (machine learning) and on the other hand, maintenance can be carried out in a needs-based or predictive manner.

IIoT business models

Digitalisation in the industrial sector brings many benefits: fast and informed decision-making, higher levels of automation, control and optimisation of processes, customer-focused marketing and differentiated customer loyalty.

Future-oriented and forward-thinking business models can result in profitable changes for everyday work in every respect. IIoT offers consist of solutions and systems that combine product and service. Billing according to operating time, control of usage conditions and wear and tear are just as feasible as a forward-looking spare parts inventory based on demand analyses. Furthermore, this makes service contracts with availability guarantee possible.

The aim is to make the best possible use of stronger networking with customers, (service) partners, suppliers, etc. Ideally, an IIoT business model creates more effectiveness, flexibility and satisfaction for all involved. Used correctly, this leads to a sustainable increase in turnover and profits.

Technical system requirements for implementation

The implementation of a digital business model for predictive maintenance depends on the right interaction of networking, powerful hardware and intelligent software. To achieve benefits such as profitable automation, cost minimisation and an increase in quality and safety, a system is needed that intelligently combines all the necessary components.

This includes the time-correct acquisition and recording of dynamic process data, reliable processing software, suitable fieldbus connections, LTE, analogue inputs and a cloud server solution. The topic of security plays a major role in the digital age, both in terms of systems and people. The optiMEAS smart systems are based on their own real-time Linux distribution and are characterised by security and robustness. This is ensured by permanent monitoring of the operating system (by watchdog and power controller) and regular over-the-air updates.

Thanks to the ring memory on the SD card, no data is lost even without a mobile phone connection. And even if the power supply fails, every measured value is securely stored via a special streaming file format. The integrated real-time extension realises fast process reactions as well as seamless acquisition and data storage.

optiMEAS offers the complete package: hardware, software, networking and support - user-friendly, scalable, easy to integrate and attractively priced for series use.

The optiMEAS solution: Interactive fleet management via dashboard

Via the cloud connection, big data can become smart data and be visualised clearly via the dashboard. The term 'dashboard' originally refers to the board that protected the coachman from splashing road dirt. The dashboard.opticloud as a modern IoT/IIoT platform enables data acquisition, storage, processing, visualisation and remote device control in real time.

Interactive maps in combination with clear display panels for data such as temperature, speed, frequency or power draw a live picture of the application. At the same time, the dashboard control panel is designed for interactive fleet management. It combines device, user and data management.

Application example rail transport

The optiMEAS smartRAIL is railway certified according to EN 50155 and IEC 61373. When used in mobile rail vehicles, it is used, for example, to locate or monitor drives, battery voltage and toilet tanks.

It measures vibrations on freight wagons or offers an integrated mileage counter. All operating states of individual components can be analysed as an overall picture. Especially when monitoring diesel or electric drives, data up to the kHz range must be recorded, stored, analysed and transmitted. Only by combining and calculating the various variables is it possible to observe wear and maintenance requirements. And this is precisely what optiMEAS specialized.