More „air to work” with Industrial Analytics

More „air to work” with Industrial Analytics

Joint project with Boge for predictive maintenance

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In order to uncover errors and operational anomalies before they occur, the compressor manufacturer Boge implements Weidmüller software for predictive maintenance.

The joint project with Weidmüller for the predictive maintenance of compressors began in October 2016. “First of all, we conducted a feasibility study to establish whether the software from Weidmüller was suitable for detecting relevant errors,” explains Georg Jager, Team Manager Turbo Machines at Boge.

“It is now clear that abnormal statuses and error patterns are detected with absolute reliability thanks to the customised Analytics solution ,” continues Jager. However, before the company reached this conclusion, the specialists from Weidmüller performed an extensive data analysis. Based on the results, an individual Analytics solution was developed for the requirements of the new Boge top product – the High Speed Turbo compressor (HST). The assignment was clearly defined: What data is required in order to predict when there will be specific damage to the compressor?

Managing Director of Boge, Thorsten Meier, on the use of Industrial Analytics:

Targeted data selection and evaluation

The High Speed Turbo compressor (HST) from Boge operates completely oil-free and sets new standards in the production of oil-free compressed air. When creating the compressor, the objective was maximum efficiency in terms of operation and maintenance. The compressors are driven by a permanent magnet motor with a high energy density. A special feature of the HST compressor from Boge is an integrated air-supported drive shaft – the prerequisite for extremely high speeds way beyond 100,000 rotations. The shaft drives a titanium impeller, which together with a special housing construction ensures extremely effective generation of compressed air.
The High Speed Turbo compressor (HST) from Boge operates completely oil-free and sets new standards in the production of oil-free compressed air. When creating the compressor, the objective was maximum efficiency in terms of operation and maintenance. The compressors are driven by a permanent magnet motor with a high energy density. A special feature of the HST compressor from Boge is an integrated air-supported drive shaft – the prerequisite for extremely high speeds way beyond 100,000 rotations. The shaft drives a titanium impeller, which together with a special housing construction ensures extremely effective generation of compressed air.

All the data came from measuring technology components that were already in the compressor, which meant that no sensors needed to be retrofitted. To judge the determined values, data scientists from the Industrial Analytics team at Weidmüller examined all the data using a statistical procedure, evaluated the actual data quality, and, together with Boge, decided how relevant the data was.

This required specific know-how of the compressed air system, as a comprehensive operating procedure was incorporated in the evaluation that was based on all the machines in the field. The experts from Weidmüller then radically sorted out the data in order to reduce the amount of data sources.

The team also had to gain experience of how the measured values correlate with each other. When performing the evaluations, it became clear that it comes down to the data pattern rather than the individual value. This creates a complex data model of normality, which is used to accurately predict damage if the values deviate from the learned model in a certain way. At the same time, continuous learning is also important for this system. The model changes with every new error message and based on operator feedback. The Analytics solution is designed in such a way that it learns from unknown situations – calculated predictions are thus increasingly precise throughout the entire operating life of the compressor.

Predict – and prevent – damage to the exact minute

The user benefits from highly-effective software that provides concrete information regarding how many minutes or hours are left before a technical problem will occur on the machine. The continued use of the compressor then determines whether or not this value withstands. If the usage scenario changes and the machine is prevented from damage, the displayed “remaining life” is extended.

Carefree with selectcair

In each case, significant damage to the technology can be prevented if users react in good time and arrange a service visit or maintenance interval. This is where it all comes together for Boge, as the compressed air specialist’s entire service package is based upon the principle of “safety first”. It does everything it possibly can to minimise the frequency and length of the machine’s downtime during its service life. Investments are no longer required in redundant systems. “In order to reach this goal, we are taking innovative steps and carrying out pioneering work in the service area,” explains Georg Jager of Boge. The result of this work is the selectcair service concept from Boge. Besides the Analytics software, it incorporates the Boge remote monitoring technology airstatus, which is integrated into all machines at the factory, along with “24-hour recovery”. Boge thereby guarantees that a machine will return to operation within 24 hours of it stopping. “Predictive maintenance is important in this respect as servicing work can be planned much earlier in advance. The machine is only switched off for the short maintenance period, making unnecessarily long downtimes a thing of the past. We are convinced that this technology will prevail in the compressed air market and will set new benchmarks.”

BOGE – market leader for compressors from Bielefeld

With over 110 years of experience, BOGE KOMPRESSOREN Otto Boge GmbH & Co. KG is one of the oldest manufacturers of compressors and compressed air systems in Germany. The company builds piston, screw, scroll and turbo compressors that are used primarily in medical technology as well as the food and pharmaceutical industries. They are also used in the key market of automotive and machine construction.

The international family-owned company employs 850 members of staff, 490 of whom are based at the headquarters in Bielefeld, and supplies its products and systems to more than 120 countries around the world.
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