PMX 和 HBM 云存储使生产过程更安全、更高效

HBM 始终致力于为客户提供高效灵活的 工业 4.0 集成解决方案,减少宕机时间,优化生产过程。 

自 1977 年成立以来,HBM 一直是世界上最著名的校准实验室之一。HBM 也是第一个获得 DKD(Deutscher Kalibrierdienst/德国校准服务)认证的校准实验室。不断扩大的投资确保了最高精度,并最大可能地满足不断增长的客户需求。

该系统全天候运行,测试的传感器的量程从4.7吨到33吨(部分加载)到100吨。也就是大约 330 千牛的力。在实际生产过程中,机械或空调系统的缺陷会导致成本上升和宕机,必须加以补救。为了实现这一目标,第一个校准系统配备了PMX、HBM的测量技术,包括云连接。

前提是现有的系统控制(PLC)不做任何改变,而将新系统监控时间减少到最低程度。

 

问题

校准系统采用 330千牛的传感器,待测零件承受了巨大的力。因此,必须确保有效控制且操作安全。此外,气候控制系统或是机械缺陷故障会导致高昂的成本和停机时间。

解决方案

博世和 HBM 一起寻找合适的硬件和软件:大量的过程和传感器数据被集成到内部 PMX 放大器系统中,以高分辨率(数千赫兹)传输到HBM测量数据采集软件。然后,数据以压缩格式以低传输速率(几赫兹)继续传输到HBM云存储。最大的优点是,数据可以根据级别提供所需的详细信息。

结果

本地的原始测量数据提供精确的、并支持人工智能分析。而压缩数据则通过云传输到 Nexeed Production Performance Manager。在那里,为了进行评估,信息被转换成指令、警告或可视化。由于 Nexeed Production Performance Manager被证明是测试站的第一个理想解决方案,HBM 将在未来几个月内将其扩展到 20个不同类型测试系统中。HBM和博世一起合作,确保 HBM 客户能获得带有分析和评估选项的创新测试和测量技术,并能在最短的时间内获得最大性能。

Plug-and-Run in Three Steps

In the first step, the operating states of the system were analyzed and the relevant points for machine monitoring were determined. This was followed by the selection of suitable sensors and measurement technology. In the test chamber – the upper part of the calibration system, where the sensors (force transducers and load cells) are located – temperature, humidity, and inclination sensors are used. In the lower area, large weights are moved by electric motors to generate the calibration loads. These mechanical processes are monitored by temperature, vibration, and inclination sensors.

In the second step, the right measuring technology was selected. The PMX is a multi-channel measuring system with data acquisition and real-time data processing. It offers comprehensive diagnostics and is parameterized via a network-compatible web server. All measured data are recorded and evaluated with a sampling rate of 19.2 kHz. The measurement and diagnostic data are transmitted to an IOT hub via the standard Ethernet interface (TCP / IP). This hub consists of a PC with suitable DAQ software.

In the third step, a suitable cloud and evaluation software was determined. What could be better than using the existing HBM cloud? The big advantage of cloud-based measurement technology is that data does not move from one storage location to another. It immediately has a utility value – in many cases even automatically due to artificial intelligence: The HBM Cloud allows to access the data worldwide – depending on the authorization – and to improve the flow of information as well as the work in international teams. An important pillar of this strategy is the choice of the "right" cloud partner. HBM chose Microsoft Azure here. This provider is particularly convincing due to the availability of dozens of global data centers, in which the data can also be stored in accordance with the legal requirements of the company's location.

Fast and Flexible Connection of Machines to Industry 4.0

Nexxed, the Production Performance Manager from Bosch, was chosen as the evaluation software. This powerful tool allows various analysis and evaluation options ranging from setting alarms and creating and sending service orders to the use of artificial intelligence (AI). Self-learning rules are stored which, later, enable plant defects to be recognized in advance and reported in time.

Your Benefits

Networking new and existing machines cost-effectively and optimizing production processes and product quality: The IoT Gateway PMX and the DAQ software enable the connection to Industry 4.0 environments to be easily implemented – without any interference with the automation logic. The exactly matched combination of control hardware and software for the realization of IT applications collects sensor and process data, transmits these, e.g. to MES, cloud applications, or systems for local monitoring of machine states, and enables process data analysis.

  • Increased productivity and efficiency
  • Plug-and-Run in three steps
  • Modularity to meet individual requirements
  • Scalable and robust measurement hardware (PMX) and software
  • Future-proof open software architecture and use of the HBM-Cloud
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