Any machine can fail, resulting in unplanned downtime. The Industrial Internet of Things (IIoT) provides a solution to avert these costly and possibly dangerous occurrences. With encoder diagnosis embedded with IIoT, manufacturers can receive early warnings through real-time data before any serious fault in the production line occurs. This data allows proactive maintenance strategies that can increase production efficiency and quality. Manufacturing heavy-duty equipment with IIoT sensors allows users to monitor the most relevant data for all rotary installations and motors in the production line. Operators can view trends and use those data to take corrective actions that extend machine life.

Encoder diagnostics in process control

Heidenhain’s advanced diagnostic system (ADS) provides built-in encoder condition monitoring. Encoders placed on the motor, drive shaft, or other rotating or moving components in the machine monitor parts that are crucial for smooth and reliable production line performance. Condition monitoring data and system diagnostics from the encoder can reveal motor performance and installations while in operation. Data can be collected and analyzed for vibration, temperature variations, frequencies, and time in motion at all encoder installations.

ADS solutions will simplify the move from preventative to predictive maintenance. This helps companies practice proactive maintenance since encoder data lets them adjust factors that otherwise would reduce machine life. Having motor installations correct avoids unnecessary problems, significantly reducing production downtime. A single prevented production stop pays back the cost of all ADS encoders at the plant.

The tool allows manufacturers to set alarms for any value and analyze graphs to compare deviations or changes and react. With ADS encoders, manufacturers can take four types of maintenance approaches before or during production:

  • Corrective – Replacement at breakdown
  • Preventative – Replacement according to schedule
  • Predictive – Replace at incipient fault; condition-based maintenance
  • Proactive – Analysis and adjustments to extend the time for change

Process management, system integration benefits

IIoT needs to be built from the component level up. With encoders, the undisputed function is process control, but the devices can also provide data to systems and networks on different organizational levels. OPC unified architecture (UA), a machine-to-machine communication protocol, enables two-way communication so the encoder can deliver data and respond to inquiries and needs from within the systems, when prompted.

More information from process-critical components means more control of plant operations. The encoder can:

  • Store, deliver detailed operational data accessible through various computer systems
  • Give ordering systems access to serial numbers in time for replacement
  • Provide time-in-motion data for performance trends of running applications