MACHINERY | EXTRUDER MAINTENANCE
Right: A Leistritz engineer demonstrates the company’s augmented reality service support
technology
to be able to enhance efficiency and quality.” Leistritz has developed a number of compre- hensive maintenance programmes for compound- ers, including the use of smart glasses. “Just recently we have also started to offer online control of the transmission bearing and main drive,” adds Jürgen Sauer. “If the customer requests it, we can access the control unit via a safe VPN link and optimise the process or solve problems quickly. We also offer customised training sessions - profes- sional handling of the extrusion line can often enhance profitability.”
Below: Senseye’s failure forecasting data can be sent to any internet-con- nected device
Guaranteed response Sauer says that an important aspect of the com- pany’s maintenance contracts is guarantees on certain reaction times and spare part availability. “We launched a repair centre in order to support customers in the quickest possible way. Worn-out liners can be exchanged within a few days, and detailed reports on wear provided. Cleaning and if necessary re-boring of cooling channels can be undertaken, as well as replacement of screw elements. We are also shortly installing a machine for disassembling screw elements.” As well as remote servicing, where the service technician in an office can directly connect to the customer’s control unit via a safe VPN channel to remedy problems, Leistritz has also recently introduced smart glasses to provide augmented reality support. Combined with intelligent software, these present customers with the opportunity to communicate easily and interactively with the Leistritz service team. The glasses comprise a camera for filming and photography, as well as a display that can quickly visualise instruction steps directly in the workplace, for example when standing in front of the machine in the production hall. All knowledge is shared in real time. Leistritz says it is currently working with a number of customers to improve control systems and modernise older extrusion lines to increase efficiency. “Extrusion lines will have to communicate in the future,” Sauer says. “This means they have to indicate if mainte- nance becomes necessary, a problem has arisen, or even if the operation needs optimising to improve quality. By installing sensors, extrusion lines can work in a self-optimising mode. The Leistritz
40 COMPOUNDING WORLD | April 2018
Industry 4.4 concept will implement this. Autono- mous quality control will become a major issue and we have developed an inline rheometer to help achieve this.” A number of additional third-party hardware and
software tools are also available to help mainte- nance engineers develop their own monitoring and maintenance systems. EZmaintain has developed a range of Industry 4.0/Internet of Things (IoT) sensors to monitor equipment perfor- mance through temperature and pressure param- eters. “Operational machines provide data that can be analysed using Artificial Intelligence tools to predict machine failure way ahead,” says Rick Modi, Founder and Chief Executive Officer of EZmaintain. “Most new machines offer sensor outputs that can be integrated into PLC for data analysis. Smart cloud base software can help to process data faster using multiple sensory inputs at any given time.” EZmaintain offers its computerised maintenance management software (CMMS) along with smart IoT sensors for monitoring extruders and com- pounding machines, which can also be used for improving preventive maintenance. “For example, companies connect our IoT vibration and tempera- ture sensors to monitor HV electric motors,” says Modi. “The sensor sends a signal via WiFi to our cloud software that processes and sends alerts to the user if the vibration of the motor increases, which could be due to bearing, greasing or overloading issues. As well as vibration and temperature, we are building smart IoT sensors in the areas of sound and pressure measurement, which will allow companies to predict failure before it occurs - reducing production losses and saving material waste.”
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www.compoundingworld.com
PHOTO: LEISTRITZ
PHOTO: SENSEYE
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