Avoid expensive machine downtime and save costs
The diesels clatter loudly, the air is hot, and it reeks of oil and grease. In the midst of the din is a satisfied-looking Johann, better known as "The Ghost. With his listening tube, he listens inside his diesel despite the immense noise. Cineastes immediately associate the scene with the film "Das Boot". It shows very vividly the old world of machine monitoring: the ear to the machine. With the devices of our sysWORXX family we make your machines readable and thus enable monitoring and control locally and remotely.
In today's industry, machines sometimes work in large, almost deserted halls. But people are still listening - hardly less intensively than on board U96. This is illustrated by the example of a lathe.
In this, axles and shafts operate at very high speeds, and fast-turning components rotate in special bearings. Due to wear, these bearings only live for a limited time, and the lathe operators have always noticed from the noise that something was wrong and called the maintenance engineer even before the machine broke down. This way, if necessary, the expensive machine was repaired before it broke down and could even be planned without losing productive time.
„Nowadays, a structure-borne sound microphone is fitted to the machine in a suitable location. This microphone continuously records vibrations and noise and transmits the data to controllers such as the sysWORXX CTR-800.“
A dashboard can be used to monitor parameters – in this example, temperature and humidity
The initial processing of the data takes place on the sysWORXX CTR-800 itself. Depending on the customer’s requirements, the pre-processed data is then sent to central computers or transmitted directly to a cloud. There, using frequency analysis of the noise profile, it can be determined – either locally or remotely – whether a bearing is approaching its wear limit; this is done far more precisely and at an earlier stage than would be possible with the human ear. In this way, it is possible to determine and predict with great accuracy when the lathe will cease to operate at its optimum working point.
sysWORXX solutions are not only used in new machines – it is also possible, with minimal effort, to retrofit old production machines and systems. The modernisation and upgrading of existing plant is achieved by tapping into new data sources to increase the productivity and service life of the machines and the efficiency of the processes.
Machine diagnostics as required
Our sysWORXX range, comprising the sysWORXX CTR-100 and sysWORXX CTR-800
Prediction is part of predictive maintenance. A company no longer needs to service its machinery at fixed intervals and have the bearings replaced, but can ‘listen in’ and take preventative action as and when necessary. This means that the procurement department can order or make spare parts available. Technicians can prepare for the replacement and schedule it for a time when production disruption is minimised.
So today, machines are ‘listening’ to other machines, whilst humans listen in – or rather, monitor the data. Cleverly designed sensors are used to monitor machines and production sites in this way. This is made possible by the controllers from sysWORXX.
The niche as a niche
Interaction between sensors and IoT controllers: The sysWORXX CTR-100 collects and pre-processes data, whilst the larger CTR-700 aggregates the data and, where required, forwards it to the cloud or receives control commands from a web panel.
This is a product range specifically designed for the Internet of Things (IoT). Consequently, the sysWORXX CTR-100 and sysWORXX CTR-800 gateways do not simply relay data to cloud servers or control rooms. Rather, they are capable of pre-processing signals from standard sensors and wireless sensors. The combined sensor, the sysWORXX CTR-100 and sysWORXX CTR-800, is therefore particularly well-suited – though not exclusively – for predictive maintenance and condition monitoring.
With the sysWORXX family, we aim to offer customers bespoke solutions based on standard products to meet specific requirements. Our target audience consists of niche customers who require solutions that cannot be provided by standard market players.
To this end, our specialists tailor the sysWORXX CTR-100 and the sysWORXX CTR-800 specifically for use in the IoT. In addition to traditional machine control interfaces such as the CANopen and Modbus fieldbuses, both controllers also offer new possibilities in this area, such as wireless networking via Wirepas Mesh.
Networks
Sensor data is acquired via radio and fieldbuses, pre-processed in the control system and either processed on-site or transmitted to the cloud.
One of the new features in wirepas is particularly appealing. As a highly energy-efficient standard, it enables devices to network flexibly with one another in a decentralised manner without the need for a central controller, thereby creating a mesh network. This enables very extensive wireless networks to be created with manageable effort, without the need for repeaters. Communication takes place variably from node to node and is also significantly less prone to interference than conventional star-shaped or tree-shaped network topologies.
Our autonomous sensors also rely consistently on wirepas. They transmit their data via wirepas mesh to the sysWORXX CTR-100 or sysWORXX CTR-800. In addition to connecting wirepas-based wireless sensors, the sysWORXX controllers are, of course, also compatible with many other sensors, such as the structure-borne sound microphone on the lathe mentioned above.
Make it machine-readable
With ‘green’ radio technology and a comprehensive range of features, the sysWORXX family paves the way for the IoT. And even though operators no longer have their ear pressed against the machine, as machinist Johann did on the boat, sysWORXX products maintain that direct connection. We make machines understandable.
Get in touch now
Your contact person: Your Sales Team at SYS TEC electronic
Department: We're happy to help:
Email: sales@systec-electronic.comPhone: +49 3765 38600-2110
