In modern industry, winding shafts are essential components, particularly in sectors such as paper, nonwoven, textile, metal, and plastic film processing. Their functionality is crucial for a smooth production process. However, like any mechanical component, they are subject to wear and potential malfunctions. An innovative approach to early detection of such issues is condition monitoring, which essentially sends the winding shaft for regular health checks by continuously monitoring its "vital parameters."
The Challenge: Complex Monitoring in a Limited Space
Spanntec Wickelsysteme GmbH from Bad Iburg, a renowned manufacturer of Tightening And Winding Technology, faced the challenge of efficiently monitoring the condition of their products. Together with byteways GmbH & Co. KG, a customized framework was developed that combines sensors and processing software to capture and analyze the condition of winding shafts in real time.
Custom Sensor Development: Precision Meets Efficiency
The requirements for the sensors were demanding: they needed to transmit time-critical data at short intervals while ensuring long battery life. The challenge was to integrate this technology into the winding shaft in a space-saving manner. By optimizing both hardware and firmware, battery life exceeding one year was achieved—surpassing the standard maintenance intervals of winding shafts. This allows for battery replacement during regular maintenance without causing additional downtime.
Data Visualization: Transparency through the CMS Dashboard
The developed Condition Monitoring System (CMS) offers a user-friendly dashboard that provides a clear representation of the collected data. Faulty conditions are signaled through visual and acoustic alerts. A statistics module allows access to historical measurement data, enabling the detection of patterns and the optimization of processes.
Integration and Future Prospects
The collected data can be seamlessly integrated into existing machine controls and displayed on various devices. By utilizing the OPC UA standard, platform- and manufacturer-independent communication is enabled—a key factor in the era of Industry 4.0.
Clear Identification with Spanntec ID
Another milestone is the introduction of the "Spanntec ID". This feature ensures that the winding shafts installed in a customer’s machine can be uniquely identified. The Spanntec ID guarantees that all displayed data corresponds exactly to the respective winding shaft. This not only provides clarity but also allows for seamless integration of data into machine control systems, ensuring a highly efficient and transparent monitoring process.
Conclusion
The preventive monitoring of winding shafts through custom-developed sensors and tailor-made software solutions represents a significant advancement in industrial maintenance. Continuous monitoring enables the early detection of potential issues, minimizing unplanned downtimes. This ensures that the "health condition" of winding shafts is always in focus, guaranteeing optimal performance.
ICE exhibition stand = Hall 6 / Stand 440
