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Counting of cycles on a knuckle-joint press using moneo RTM

Quantity-based process monitoring for quality assurance

At a work station for final inspection of pressure sensors, different types of production equipment are used. For testing, electrical contact is established between the production equipment and the pressure sensor via an M12 connector.

The frequent repetition of this process results in wear of the sockets on the production equipment. In the past, time-based maintenance of the sockets was performed. A shift to quantity-based maintenance is planned to allow for a more efficient use of resources.

The initial situation:

Lifting and closing cycles were not recorded, documented or visualised in the past. No threshold monitoring or alarm and information systems were used, resulting in a lack of transparency in the maintenance process. Wear parts were replaced on a monthly basis. Unplanned process standstill due to the failure of production equipment resulted in higher costs. No planning scenarios could be created due to the lack of history data.

Aim of the project:

Shifting to a needs-driven maintenance of wear parts. For this purpose, the lifting and closing operations are to be detected using position sensors. When a limit value is reached, a corresponding information (alarm) is to be generated.

The implementation:

At ifm prover gmbh, moneo RTM is centrally installed on a server. The IO-Link masters are connected to the server via an internal VLAN.

ifm offers a wide range of automation components. For this application, the DX2055 multifunction IO-Link display was chosen, as it meets all the requirements of the application.

Case 1 – insulation test: position sensors for the detection of the lifting cycles.

Case 2 – leak test: position sensors for the detection of the closing cycles of the protective cover.

Both sensors are connected to the DX2055 multifunction IO-Link display. It transmits the counter value to moneo RTM via the IO-Link master. Both process values allow conclusions to be drawn regarding the quantity produced at the respective work station. After maintenance, the counter in the DX2055 multifunction IO-Link display is reset via a key-operated switch.

The result:

The maintenance process is now transparent. The use of resources has been optimised and the costs haven been reduced.

Bottom line:

The changeover was successful. A return on investment will be achieved in 1.4 years.

System structure

  1. Inductive sensors (IFC246)
  2. Optional reset option (e.g. key-operated switch)
  3. Multifunction IO-Link display (DX2055)
  4. IO-Link master (AL1350)

Dashboard

Get the big picture on the moneo dashboard. The dashboard provides the user with an overview of the relevant process values for this plant.

  1. Current count (insulation test)
  2. Traffic light display of the warning and alarm values (insulation test)
  3. Traffic light display of the warning and alarm values (leak test)
  4. Current count (leak test)

Tasks & tickets: managing limit values

An individual threshold is defined for each process value. In this way, maintenance is informed in time (defined alerts via dashboard and/or email possible).

Application-specific:

  1. Warning threshold (yellow): A filter change will soon be necessary. Maintenance is informed by email.
  2. Alarm threshold (red): A filter change is immediately required. The maintenance and production departments are informed by email.

Manage ticket processing rules

Definition of email alerts based on warning and alarm rules via the integrated wizard

  1. Definition of thresholds (5) and data sources (6)
  2. Defines which rule is applied
  3. Defines the warning or alarm urgency
  4. Defines the email recipients
  5. Definition of the relevant thresholds
  6. Definition of the corresponding data sources

The email generated from within moneo already contains ticket information:

  • affected data source
  • value that was exceeded or not reached
  • ticket priority
  • timestamp