MORE AVAILABILITY
PREDICTIVE MAINTENANCE
If the manipulator shuts down, so do the press and furnaces. This usually also impacts downstream processes. Our digital maintenance tool for rail-bound forging manipulators helps to increase the availability of your system and avoid unplanned shutdowns.
PREVENTION
MACHINE AVAILABILITY – AN ABSOLUTE MUST
Maintenance and servicing are very important to ensure the availability of the system and avoid unplanned shutdowns. This involves both work to be carried out on schedule according to the manufacturer’s specifications as well as the timely replacement of components and drives.
BOTTLENECKS
In industrial forging, it is not only the press that is important, but also the dynamics and precision of the workpiece manipulators.
They can only fulfill their function if all seven axes are able to function reliably and precisely, and the hydraulic control system works perfectly. Such highly dynamic machines are usually the “bottleneck” in the production process.
CHAIN REACTION
A shutdown of the manipulator also leads to production interruptions in downstream processes such as heat treatment and mechanical processing. In the event of an unscheduled shutdown of the forming unit, not only the energy for heating but also the material is lost. Furthermore, the operating staff cannot be employed for the time being.
To meet these requirements, DANGO & DIENENTHAL has developed a digital maintenance tool for rail-bound forging manipulators which consists of three modules that build on each other:
FUNCTION
The machine’s operating hours counter, calendar, and respective maintenance schedule provide the necessary data for the digital maintenance calendar. The digital maintenance calendar replaces the manual logging of regular maintenance work and ensures that all maintenance work is carried out on time.
This makes it much easier for the maintenance team to plan and carry out the necessary maintenance work.
OVERVIEW
- Summary of currently pending and completed work
- Acknowledgment of work steps
- Information on upcoming maintenance work to be carried out by D&D
FUNCTION
The “Preventive maintenance” module provides an indication of the current status in the life cycle of the following function groups:
- Tongs
- Lifting system
- Auxiliary drives
- Pressure generation
Data from existing information sources (operating hours, travel distances, rotations, loads, etc.) are recorded, stored, and evaluated for this purpose.
OVERVIEW
Color-coded service life indicators answer the following questions at a glance:
- How long has this component been in operation?
- How much longer can the component be used before it needs to be replaced?
- When must the component be ordered at the latest so that it is available for replacement?
In addition, users can call up a complete overview of the monitored function groups on the machine visualization. This allows critical situations to be identified and prevented.
FUNCTION
With the “Predictive maintenance” module, functional groups are equipped with additional sensors. The data collected by these sensors makes it possible to record the current status of important components and to identify trends.
In this way, early intervention can be initiated if limit values are approached or if there are unusual jumps in values, thus preventing unplanned machine breakdowns.
OVERVIEW
- Test programs check the monitored functions of the machine using a predefined movement profile.
- Current measured values are compared with the results of the test run in the new condition.
- The expected remaining service life of the monitored components is updated based on this data.
