This is how you optimize your plant availability and reduce costs through predictive maintenance.
What is the main advantage of digital servo gear motors with predictive maintenance sensors for my manufacturing company?
The main advantage is the significant reduction in unplanned downtimes, which leads to higher plant availability und lower operating costs . ATEK Drive Solutions GmbH helps you leverage these potentials.
How does predictive maintenance work with these motors?
Integrated sensors continuously collect condition data such as vibration and temperature. This data is analyzed to predict maintenance needs, before a failure occurs and expensive repairs become necessary.
What sensor data is particularly important and how is it analyzed?
Important data includes vibrations (often captured triaxially), temperature, and current consumption. The analysis is performed using FFT (Fast Fourier Transformation) for frequency patterns and machine learning algorithms for anomaly detection and forecasting.
Is implementing predictive maintenance systems complicated?
The introduction requires an initial investment and specific expertise. However, ATEK Drive Solutions GmbH supports you with consulting and system solutions, to simplify the process and achieve a quick ROI , often within 12-24 months.
For which applications are these smart drives particularly suitable?
They are ideal for demanding applications in industries such as machine and plant engineering, packaging industry, automotive industry, and logistics, where precision and availability are crucial .
What is HIPERFACE DSL® and what benefits does it bring?
HIPERFACE DSL® is a single-cable technology, which transmits power and sensor data together. This reduces wiring effort, simplifies installation, and increases data reliability..
How important is the correct calibration of the sensors?
Die correct calibration of the sensors according to OEM specifications is essential for the reliability of the system. Incorrect baseline values can lead to misdiagnoses and unnecessary maintenance , which undermines the effectiveness of the system.
Can ATEK Drive Solutions also offer customized solutions with predictive maintenance?
Yes, ATEK Drive Solutions specializes in custom drive solutions.We integrate predictive maintenance functions precisely into special gearboxes and complete drive trains, to meet your specific requirements.
Digital servo gear motors with predictive maintenance sensors significantly minimize unplanned downtimes , often by over 50%, and can extend the lifespan of components by up to 25%, which increases overall equipment effectiveness.
The technology is based on precise sensors (e.g., vibration, temperature sensors), intelligent data analysis using FFT and machine learning as well as efficient interfaces like HIPERFACE DSL® for reliable condition monitoring.
A successful implementation requires careful planning, correct sensor calibration, and employee training; ATEK Drive Solutions GmbH provides targeted consulting and system solutions , to realize the, um den return on investment (ROI) often within 12-24 months. .Discover how digital servo gear motors with integrated predictive maintenance sensors can revolutionize your production and make unplanned downtimes a thing of the past. Learn all about the technology, advantages, and applications.
The future of drive technology is intelligent and predictive. Digital servo gear motors with predictive maintenance sensors enable unprecedented plant availability. Would you like to know more about the benefits for your company? Contact now contact our experts now!
Are you interested in predictive maintenance for your plants? Talk to our experts!
Now discover potential!
Understand the basics: What lies behind the advanced technology?
Digital servo gear motors with predictive maintenance sensors enable continuous plant operation without unexpected interruptions, maximize availability, and reduce costs. ATEK Drive Solutions GmbH supports you in modernizing your maintenance.
The basis: Digital servo gear motors
Digital servo gear motors combine precise control with robust gearbox technology for demanding applications. They enable up to 15% higher cycle rates with constant precision in packaging machines. A servo motor with a digital interface offers additional options.
The plus: Integrated predictive maintenance sensors
As early warning systems, these sensors continuously capture condition data such as vibration and temperature. A machine tool manufacturer optimized maintenance intervals by an average of 20%. Information on sensor-monitored brakes.
The core: Predictive maintenance as a strategy
Predictive maintenance analyzes sensor data to forecast maintenance needs before failures occur. According to a Deloitte study, this can extend component lifespan by up to 30%.Use data intelligently: From sensors to valuable decisions
For valid data, the correct placement of sensors, e.g., triaxial accelerometers near bearings, is essential. SICK recommends such configurations for vibration analysis. Related is the integrated gear motor with remote diagnosis.
- Importance of correct sensor placement for valid data.
- Use of analytical methods such as FFT and machine learning for deep insights.
- Detection of anomalies and forecasting failure probabilities through advanced algorithms.
- Role of HIPERFACE DSL® for efficient data communication and reduced wiring.
- Increase in data reliability and simplified installation through single-cable technology.
- Achieving comprehensive diagnoses through sensor fusion that combines data from various sensors.
Deep insights: Analysis with FFT and machine learning
Methods like Fast Fourier Transformation (FFT) for frequency analysis and machine learning algorithms detect anomalies and predict failure probabilities. A food producer increased failure prediction accuracy by 25%.
Efficient communication: The role of HIPERFACE DSL®
The single-cable technology HIPERFACE DSL® transmits power and sensor data together, reduces wiring effort, simplifies installation, and increases data reliability. – advantageous in complex drive system integrations..
Holistic view: Sensor fusion for comprehensive diagnoses
Sensor fusion, the combination of data from various sensors (temperature, speed, vibration), provides a complete picture of the motor state. Omron uses this to maximize the reliability of predictive maintenance solutions.Realizing benefits: More than just avoiding failures
Maximum availability: Minimize unplanned downtimes
Early detection of problems allows planned maintenance. This often reduces unplanned downtimes by over 50% in the first two years. An automotive supplier reduced downtime at critical presses by 60%. A servo-ready gear motor system supports this.
Longer lifespan: Optimal use of components
Continuous monitoring and optimized operating conditions preserve components. The lifespan of servo gear motors can be extended by up to 25%. A logistics center extended replacement cycles for its conveyor drive systems.
Reduce costs: Efficient maintenance pays off
Fewer downtimes and needs-based maintenance reduce costs. Reductions in maintenance costs of 10-40% are realistic. GES Deutschland GmbH reports customers who reduced repair costs by a third through optimized servo motor maintenance.See practical examples: Where the technology has already proven itself
In machine and plant engineering, digital servo gear motors with PdM sensors ensure the performance of robots and machine tools. A CNC machine manufacturer improved axis positioning accuracy by 5% and reduced maintenance costs by 15%. Relevant for integrated gear motors for CNC machines..
- Ensuring the performance of robots and machine tools in automation technology.
- Konkrete Erfolge wie verbesserte Achspositioniergenauigkeit und gesenkte Wartungskosten bei CNC-Maschinen.
- Increase in efficiency and productivity as well as reduction of waste in the packaging industry.
- Minimization of packaging errors at beverage fillers through predictively maintained servo drives.
- Forecasting motor failures and reducing unplanned downtimes in automotive assembly lines.
Packaging industry: Increased efficiency and reduced waste
These drives enable fast, precise operations in the packaging industry and increase productivity. A beverage filler reduced waste from packaging errors by 8% using predictively maintained servo drives.
Automotive industry: Predicting failures in assembly lines
Manufacturers predict motor failures in robots on assembly lines. Analysis of vibration and torque data reduced unplanned downtimes of a welding robot line by 20%.Mastering implementation: Challenges and clever solutions
Investment and expertise: Realistically planning costs and know-how
The implementation of PdM systems requires initial expenditures for sensors and software. A cost-benefit analysis often shows an ROI within 12-24 months. Building IT expertise or partnering with companies like ATEK Drive Solutions GmbH is crucial.
The devil is in the detail: Critical importance of sensor calibration
Exact sensor calibration according to OEM specifications is critical for system reliability and is often an underestimated source of errors. Incorrect baseline values can lead to misdiagnoses and unnecessary maintenance.
Man and machine: Successfully involving employees
Comprehensive training on new systems and data interpretation is essential. Companies with early team qualification achieve up to 30% faster amortization of PdM systems.
Smart combination: Developing hybrid maintenance strategies
A hybrid strategy that combines PdM for critical drives with condition-based monitoring for less critical ones optimizes resource utilization. Main drives are monitored predictively, auxiliary drives are monitored condition-based.
The implementation of digital servo gear boxes with PdM sensors is a strategic step towards efficiency and competitiveness. Precise data collection and analysis minimize downtime and maximize asset lifespan. Planning, correct implementation (especially sensor calibration), and employee training are crucial. ATEK Drive Solutions GmbH is happy to advise you.
