First IoT ConnectBoxes installed in demo factory at RWTH Aachen University
Retrofitting at its best! In the demo factory of RWTH Aachen University, we were able to digitize three existing production units. A wide range of sensors were installed in order to pick up the required data via the IoT ConnectBox and transfer it to our IoT platform. Furthermore, the data is integrated into the demo factory’s ERP system with the help of interface programming.
In total, we have digitized a band saw, a belt grinder and a swing grinder for the purpose of condition monitoring and predictive maintenance. Since all three machines are needed for contract manufacturing, unforeseen downtime is costly. Thanks to the IoT ConnectBox, all three production systems have now been digitized. In the future, problems can be detected at an early stage and downtimes avoided. Both analog and digital signals can be handled by the IoT ConnectBox.
All machines were retrofitted with smart sensors.
From now on, the band saw’s temperature, vibrations, feed rate and blade speed are monitored. Even the smallest deviations that could cause a system failure are thus detected at an early stage. On the basis of the data supplied by the installed sensors, conclusions about the condition of the saw can be drawn:
- the temperature provides information about whether the saw is being used correctly. If the temperature is too high, the saw blade will suffer excessive wear. The transducer, which is needed to operate the sensor, also has monitoring mechanisms that allow it to detect and quickly correct any malfunctioning of the sensor. A device with pneumatic connection for blowcleaning the sensor is also integrated. This prevents the sensor from becoming contaminated by chips and cooling water.
- The speed of the saw blade indicates whether the correct cutting speed for the material is being maintained. A speed that is too high or too low can also lead to increased wear.
- Via the feed system of the tool table, the correct feed rate for machining can be checked. Frequent deviations can also cause increased wear of the saw blade.
- Vibration of the saw blade can give an indication of its state of wear. An elevated RMS value may mean that the saw blade needs to be changed or that the drive is damaged. Therefore, the RMS value is monitored via an analog signal and an alarm is triggered if the limit value is exceeded.
SwingGrinder + extraction unit for cooling water:
From now on, the filling level of the unit can be monitored, and the attachment head will be checked at the SwingGrinder:
- The signal indicating that the level had fallen below the limit is routed from the internal controller of the cooling water system to the IoT ConnectBox via an optocoupler. For this, the circuit diagrams of the unit were requested directly from the manufacturer.
- The inductive sensor can be used to check whether the correct attachment head was used for machining. There is one attachment head for aluminium and another for stainless steel. Via the time stamp, it is possible to ascertain which head was used on which part
The belt grinder is now monitored by a vibration sensor with a frequency response up to 6000 Hz.
In this high range, bearing damage, imbalance in the motor, etc., can also be detected To this end, the RMS peak (digital signal) is monitored in addition to the normal RMS value (analog signal).
Are you interested in the IoT ConnectBox for your application? Then please call us at +49 241 5109-260.
RNA receives first order for digital feeding system
Shortly after the successful takeover of Hofmann & Stirner Zuführsysteme GmbH, which now operates under the new name of RNA Digital Solutions GmbH, we received our first digital order. The early …
Centrifugal feeders BaseType Z
Our feeding system BaseType Z is based on a centrifugal feeder, which was integrated in the complete machine. Through the standardization of additional components, we were able to further optimize…
RNA’s STF elevator feeder: solution for ‘highest’ requirements
To stockpile parts and transfer them safely to downstream processes, RNA offers a wide range of vibration and belt-type hoppers. Our belt-type hoppers are designed as horizontal hoppers, inclined…
Rhein-Nadel Automation GmbH (RNA) übernimmt das Münchener Startup Hofmann & Stirner Zuführsysteme GmbH
In November this year, RNA purchased the Munich start-up company Hofmann & Stirner Zuführsysteme GmbH. That way, RNA is securing important know-how in the field of artificial intelligence and…