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Predictive Maintenance - Identify today what won't work tomorrow

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

optiMEAS Predictive Maintenance

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

In the field of IoT, the technical possibilities for networking the elements involved are manifold and by no means 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 optimization begins with the use of data in further processing to information. The more facts are available, the more soundly a decision can be made. In the field of mobile machines, Internet-based telematics and teleservice solutions enable remote diagnosis and maintenance of machines in operation. The analysis of real operating and usage data can also help to improve products in machine development.

The progress of digitisation now makes it possible to monitor entire processes, including the inclusion of external data (e.g. weather or traffic). Conventional telematics solutions are no longer sufficient here. Measurement and control technology must be intelligently combined. Smart Data in this context means the continuous acquisition and evaluation of the combination of many different real-time and historical data in order to recognize patterns, derive trends and finally make predictions.

Smart Data Management can be used to make statements about 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 according to requirements or with foresight.

Business models IIoT

Digitization in the industrial sector brings many advantages: fast and well-founded decision-making, a higher degree of automation, control and optimization of processes, customer-oriented marketing and differentiated customer loyalty.

Future-oriented and thoughtful 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. Invoicing according to operating time, checking conditions of use and wear and tear can be implemented just as easily as a forward-looking spare parts inventory based on demand analyses. Furthermore, service contracts with availability guarantee are possible.

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

Technical system requirements for implementation

When implementing a digital business model for predictive maintenance, the right interaction of networking, powerful hardware and intelligent software is crucial. In order to achieve advantages such as profitable automatisms, cost minimization and an increase in quality and safety, a system is needed that intelligently combines all the necessary components.

This includes the timely acquisition and recording of dynamic process data, reliable processing software, suitable fieldbus connections, LTE, analog 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 a proprietary real-time Linux distribution and are characterized by security and robustness. This is ensured by permanent monitoring of the operating system (by watchdog and power controller) as well as 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 allows fast process reactions as well as complete 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 production.

The optiMEAS solution: Interactive fleet management via dashboard

Big Data can be turned into Smart Data via the cloud connection and can be clearly visualized via the dashboard. Originally, the term "dashboard" goes back 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, visualization and remote device control in real time.

Interactive maps combined with clear display panels for data such as temperature, speed, frequency or power draw a live image 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, and 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 a complete picture. Particularly when monitoring diesel or electric drives, data must be recorded, stored, analysed and transmitted up to the kHz range. Only the combination and calculation of the various variables makes it possible to consider wear and maintenance requirements. And this is exactly what optiMEAS specialized.