Digital condition monitoring of transport systems
Overhead conveyor systems are used in assembly production lines in the automotive and other industries. The failure of individual support frames can lead to the stoppage of entire production lines. A condition monitoring system based on the MICA® Edge computer detects wear at an early stage and thus prevents unplanned downtime.
Overhead conveyor systems in production lines transport e.g. machine parts or chassis through individual assembly sections. Worn rollers or damage to drives can lead to the failure of individual support frames, which inevitably leads to a bottleneck of the entire production line due to the serial guidance of the overhead conveyor. To prevent failures, HARTING offers a solution for digital condition monitoring of the supporting frames. Here, creeping wear is detected and a warning of a potential failure is issued in good time. The system helps reduce unplanned failure of the overhead conveyor. Maintenance costs can also be significantly reduced by condition-based maintenance. The goal is to achieve higher overall equipment effectiveness (OEE) of the suspended conveyor. Since the condition-monitoring solution is designed to retrofit existing systems, it is also possible to extend the lifetime of transport systems.
The system consists of two highly sensitive sensor boxes and a MICA Edge computer which directly evaluates the sensor values and transmits them to the control system via the integrated Wi-Fi function. The sensors continuously detect vibrations on the rotors, the frequency of the motor current, the motor current, and the temperature of the drives. If a threshold value is exceeded, the moving-state monitoring set sends a message to the maintenance support department via the control system. Affected supporting racks are taken out of service in targeted manner and serviced.
The condition monitoring set can be retrofitted for all types of transport systems with slow moving components, e.g. escalators, elevators and conveyor belts. Thanks to the IP 65/67 protection class of the sensor boxes and the MICA, the system can be operated without problem in numerous ambient conditions. The solution was developed in close cooperation with an automobile manufacturer and FormsMedia, a company in the MICA.network partner network.