Detect causes of faults faster and reduce unplanned downtime

The Technology

With ibaPDA, the acquisition of measurement data is powerful, flexible and continuous. Thanks to the comprehensive connectivity of the iba system, not only data from the control systems are recorded, but also sensors (e.g. pressure or displacement signals) can be directly connected to the ibaPDA via ibaPADU. Thus, complex installations and configurations of mobile systems are not necessary. In addition, ibaCapture records video information synchronously to the other measurement data and stores it continuously. Both measurement and video data are available to the plant operator online and historically in the ibaQPanel-based visualization. Furthermore, maintenance staff and technologists use the powerful analysis tool ibaAnalyzer to analyze the historical measurement and video data both interactively and automatically. Due to the consistent and continuous data acquisition, errors can be analyzed in detail already after their first occurrence and measures for error elimination can be defined. Since the recording duration of the data is only limited by the granted storage space, Hirschvogel uses the iba system not only for current malfunction and weak point analysis, but also for long-term analysis.

Example:

Detecting faults with video and signal recording

Problem:

The steel blanks sporadically stick together at the outlet of the heating system. Each time, the machine operator has to interrupt production and eliminate the problem manually.

Solution:

Using time-synchronized recording of video and process data, the induction heating process was analyzed in depth. This allowed the specific triggers of the problem to be identified: By making a mechanical change and optimizing the outlet, it was possible to avoid stitching and the subsequent sticking of the blanks. 
This source of error and the resulting machine downtimes could thus be permanently eliminated.