Predictive Maintenance is Reality Easy, Affordable Monitoring Increases Uptime

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1 OEM & System Integration Weighing Components 18 News Predictive Maintenance is Reality Easy, Affordable Monitoring Increases Uptime Our collection of case studies demonstrate how predictive maintenance can provide benefits for typical weighing applications. Products offering predictive maintenance are easy to install and run locally without having to transfer big data or worry about security. Traditional maintenance means performing preventive actions at certain intervals and repairing equipment when something breaks. In contrast, predictive maintenance allows you to reduce these costly activities without unwanted machine stops. Such capabilities are based on condition monitoring of the equipment performance, which predicts future breakdowns and allows you to take action before they happen. Available from day one However, many potential users may incorrectly believe predictive maintenance is tied to complex big-data processing in a cloud outside their company. We offer weighing technology that includes predictive maintenance inside the equipment without sending any data outside the company. Algorithms for prediction have been designed by our experts, who know all potential errors from practice. The prediction functionality is operational from day one. It is not based on results from breakdowns that actually have to happen before they can be predicted. Continue reading the case studies in this newsletter about drum filling and pallet and tank weighing to see how you could improve the uptime of your machines.

2 Filling and Blending Less Maintenance and Less Risk? Reliable Filling and Blending A filling and blending terminal connected to a weighing platform with digital load cells provides condition monitoring information for predictive maintenance. This smart set-up can reduce machine stops for preventive maintenance without increasing the risk of productivity damaging downtime for unexpected repairs. The IND570fill POWERCELL weighing terminal is the ideal controller for semiautomatic filling machines. It features dedicated filling software with sophisticated algorithms and digital inputs and outputs for direct control of filling valves. This effective combination can be used instead of a small PLC system or to complement a larger system by directly controlling delicate filling processes while improving filling speed and accuracy. Predictive maintenance increases uptime The IND570fill POWERCELL terminal permanently monitors performance of each individual load cell of the PowerDeck floor scale and warns operators when inspection is needed. IND570Fill-POWERCELL can even send a direct message to the control system or to the mobile phone of the production manager. These features mean maintenance only occurs when it is actually needed, reducing the number of machine stops for preventive maintenance and reducing costs as well as the risk of rework and wrong batches. Floor scale for predictive maintenance The combination of the new PowerDeck floor scale family with the IND 570Fill weighing terminal use POWERCELL technology for condition monitoring to allow predictive maintenance. The PowerDeck is available from 300kg up to 12,000kg with legal for trade approvals according to OIML and NTEP. 2

3 Intelligent load cells provide better accuracy The IND570fill POWERCELL terminal is combined with the PowerDeck weighing platform, which includes intelligent POWERCELL PDX load cells with integrated microprocessors. This enables on-board analog-to-digital conversion and eliminates the error-prone transmission of analog values over distance. Environmental factors, such as temperature changes and vibrations, are also mitigated. In addition, the microprocessor corrects the linearity error of mechanics and electronics. broader control solutions. Cycles can be looped to implement continuous processes. Auxiliary devices, such as mixers, vibrators or conveyors, can be integrated into the process. Such customized cycles can be easily configured within IND570fill standard software, eliminating the need for specialized programming. Self-learning saves effort New material setup is simplified and accelerated by the terminal s learn mode. Operators can program a new target with +/- tolerance values and let IND570Fill algorithms automatically calculate the ideal fine feed and spill values during the first run. Automatic Spill Adjustment Mode continuously improves results by accounting for environmental changes that affect the amount of material still in flight after all the feeding equipment is shut off. Integrated statistics on the weigh-in and weigh-out cycles provide data to help identify system adjustments that can shorten cycle times, reduce waste and improve margins. Customized blending and filling applications The terminal enables filling of single materials or blending of up to six materials using one- or two-speed feed control. Two-speed settings ensure that material transfer is both fast and accurate. Weigh-in cycles are easily combined with weigh-out cycles to create Learn more Modern weighing technology with predictive maintenance capabilities: 3

4 Logistics Skip Daily Checks When Relying on Predictive Maintenance Daily inspections for safety-relevant weighing equipment in a logistics hub are costly. Weigh modules with predictive maintenance features provide permanent condition monitoring that detects performance decreases without delay. Shipping documents include declaration of weight. Many logistics hub operators use this information to determine storing place and to avoid overload of shelves. However, warehouse operators typically don t trust the documentation and perform their own weight check before passing pallets and boxes to the automated warehouse system. Predictive maintenance reduces ongoing effort A logistic hub operator decided to abandon unreliable daily preventative maintenance checks at the end of every work shift for the safety relevant weighing stations. He upgraded the existing weigh modules with traditional analog load cells to PowerMount weigh modules with POWERCELL load cells, the new load cells from METTLER TOLEDO. These load cells feature integrated microprocessors that perform continuous condition monitoring to provide predictive maintenance information. They immediately detect debris that falls from pallets and obstructs the free motion of the scales. The load cells also immediately detect damage from careless pallet placement onto the conveyor scale by forklift trucks. Fast and easy installation Our service engineer simply replaced the old weigh modules with PowerMount weigh modules. The cables were easy to install into existing conduits because of plug-and-play connectors and availability of pre-configured cables with different lengths. Junction boxes to connect individual weigh modules were not required anymore because the POWERCELL inside the PowerMount can be daisy-chain connected and the length of the cables doesn t matter. Cost savings and even more reliability The logistics operator saved the cost and effort of daily inspection tours that were not always executed because of heavy workloads and a lack of understanding about why it was necessary on the part of some employees. The hub operator Weigh module for predictive maintenance The POWERCELL load cell inside the PowerMount weigh module has an integrated microprocessor that processes weight result. It can be daisy-chained with other weigh modules directly to the weighing terminal. 4

5 also saved the frequent training sessions for the inspection team because of high turnover among workers. In addition, they now have the capability of analyzing the error-log file to identify which forklift driver stresses the conveyor so they can provide additional training to prevent unnecessary scale wear and tear and prolong the life of their investment. Conveyor Scale 1 Conveyor Scale 2 Conveyor Scale 3 Conveyor Scale 4 `` `` The IND780-PDX weighing terminal with TraxEMT software constantly monitors loads cells, records errors and alerts the user prior to serious trouble. `` 5

6 Predictive Maintenance Can Your Operations Continue? Save Batches When Failures Happen A fully digital load cell with self-monitoring features provides unique accuracy and predictive maintenance information for tank and silo scales. Run-flat functionality can allow production to continue despite load-cell failure until the time is right for repairs or a batch is finished. POWERCELL PDX load cells inside PowerMount weigh modules are truly digital. They host an on-board microprocessor to monitor external influences that affect weighing accuracy. By compensating for temperature changes, vibrations, hysteresis and non-linearity, they provide extraordinarily accurate results. True predictive maintenance Self-monitoring POWERCELL PDX load cells, in combination with an IND570 POWERCELL weighing terminal, maintain weighing accuracy by alerting operators if potential problems, such as those caused by degrading load cells, occur. A built-in breach-detection system also sends an alert if the enclosure is damaged. This allows replacement at the first sign of trouble and before moisture causes weighing errors or scale failure. Keeping production running Run-flat mode is designed to allow a scale to be used even if one load cell has failed for applications in which downtime is costly or a batch would be lost if a machine stopped. The total weight applied is estimated based on values provided from remaining load cells. Depending on the application, the estimation will be less accurate, but it may be sufficiently precise to allow operations to continue until the scale is repaired. Ideal for tanks and silos PowerMount weigh modules are ideal for tank, silo, reactor and hopper weighing. They allow you to run scales with high uptime despite reduced inspection frequency to save costs. ` ` `` 6

7 The robot places the IoT device onto the WMS weigh module to verify integrity and completeness. OPC UA Communication in Action For Quality Control of IoT Devices The Open Integrated Factory demonstration showcase is the result of a close collaboration between METTLER TOLEDO, SAP and various partner companies. As one of those partners, we provided a highresolution weigh module for completeness control of an IoT device. The goal of the Open Integrated Factory is to show how automation technology and business software are operating together more closely than ever before. The installation includes robots, printers, conveyors, vision-inspection systems and a high-resolution weigh module. High-precision weighing made for automation The WMS weigh module with robust stainless-steel housing and optional IP66 protection is designed for easy integration into machines. It provides robust overload protection against excessive forces, which can occur in case of the malfunction of an automated-handling device. An internal test weight allows verification of the weigh module s functionality any time it is needed. If a deviation is detected, the weight is used for re-calibrating the weigh module to restore pre-accident measuring performance. Easy and fast commissioning The weigh module communicates with the partner devices via OPC Unified Architecture (OPC UA), a machine-tomachine communication protocol for industrial automation developed by the OPC Foundation. It uses a standard solution that provides OPC-UA connectivity for almost all METTLER TOLEDO weighing devices. `` 7

8 Quality Control for Electronics Three Applications, One Proven Tool Calibrating Dispensing and Coating Devices The new WKC weigh module is a high-precision instrument designed for seamless integration into small spaces. It is ideal for gravimetric calibration of volumetric dispensing devices used for bonding and coating processes in mass manufacturing of printed circuit boards. Tablet testing in lab automation Tablets are comprehensively tested to verify compliance with regulations and weight is an important parameter. The WKC weigh module, with its flat design, can be seamlessly integrated into automatic tablet-testing instruments. IC-packaging in semiconductor manufacturing The WKC weigh module is ideal for calibrating dispensing devices for coating, packaging and encapsulation processes. It can also be used as a destruction-free quality control method to measure how much material is applied onto a surface. Dispensing devices for mobile phone manufacturing During the manufacturing of mobile phones, coating processes seal and protect electronics against moisture ingress and cameras are affixed with glue. The WKC weigh module is ideal for calibrating dispensing devices for these delicate processes. 8

9 Integrated calibration The weigh module features an internal test weight. This allows you to check weighmodule functioning at any time, even if it is loaded. Additionally, the weigh module can be adjusted if deviation is detected during the test. Fast installation Standard M12 connector sealing and coated connection cable enables fast commissioning and reliable data communication. Robust housing Fully enclosed stainless-steel (EN / 304L) housing protects the weigh module against aggressive materials. Learn More Adaptable weighing pan A detachable weighing platform with threaded holes allows for the installation of specific custom productholding adapters. WKC high-precision weigh module Three models with capacities of 220, 620 and 6,200 grams Smallest readability is 0.1 milligram Smallest repeatability is 0.1 milligram RS422 interface as standard PLC connectivity as accessory for PROFINET, PROFIBUS, EtherNet/IP, DeviceNet, and CC-Link Learn more about 9

10 Intelligent Sensor Management Sensors That Learn Give You the Most Reliable Diagnostics To maximize product quality and yield, you need to know if your sensors are performing correctly. That is why we have always made diagnostics the main focus of Intelligent Sensor Management (ISM ). And with our new version of ISM we offer a world s first sensors that actually learn from your processes to give you unequalled diagnostics performance. Breakthrough innovation Since its launch in 2006, ISM technology has gone on to help hundreds of companies across the world increase process reliability, reduce maintenance costs and simplify sensor handling. One of the central features of ISM is its diagnostic algorithms that predict when sensor maintenance, cleaning or replacement will be required. With our new, advanced algorithms we provide a breakthrough innovation sensors that actually learn from and adapt to processes. This gives you exceptionally reliable diagnostics that are specific for every single process. No more guesswork ISM sensor diagnostics do not give you raw data that has to be interpreted: they provide easy-to-read tools that tell operators what needs to be done and when to keep sensors and your processes running reliably. Sensor diagnostics mean you can confidently plan maintenance for when it is actually needed neither late which can damage production, nor early when it is not required. Keep your processes in the lead There is a huge variation in processes found across manufacturing, so the latest ISM sensors actually adapt to the conditions they operate in. As a consequence, ISM diagnostics represent each and every process more accurately than ever before. This enables you to further optimize maintenance and calibration procedures to get the most out of your resources. Diagnostics speed saves time Exchanging sensors can lead to risk exposure as a measurement point is taken off-line, so a fast ramp-up that gets you back to reliable operation quickly is key. To always ensure your sensors are up and running as fast as possible, the new algorithms provide accurate diagnostics in only 24 hours. They not only learn they teach In some applications, process conditions mean that it can take some time for algorithms to stabilize and give you precise diagnostics data. We have solved this by giving ISM sensors the ability to learn from other sensors that have already been used in an application. For example, when a ph probe is removed from a process and is connected to our 21 CFR part 11-ready isense software, information on the conditions of that particular process can be stored as an application profile. This profile can then be transferred into a different ph sensor. When this second sensor is installed in the same process, it carries the knowledge of its predecessor and does not need to acclimatize. And if process conditions alter, sensor diagnostics adjust themselves appropriately. 10

11 I can transfer the knowledge of one sensor to another with just a click. Sensor maintenance Now diagnostics are accurate as soon as a sensor is installed and you can be sure you are conducting maintenance when it is necessary. That means you can always be certain your sensors are performing at their best. Beyond plug and measure With the application profile database on isense and the ability to calibrate ISM sensors away from the process, you can build a stock of ready-to-go application specific sensors. Now you can replace a sensor at the measurement point in seconds without having to adjust the transmitter. For today s processes, tomorrow s ISM developments such as new advanced diagnostics and mobile apps that provide quick sensor checks on the go mean that ISM will remain the leading technology in analytical measurement. `` Learn More Sensors for your processes METTLER TOLEDO Process Analytics in-line sensors cover ph, conductivity, gas and dissolved oxygen and many other parameters. We offer flow-through, stationary and retractable sensor housings. Our process connections include Ingold, ANSI, Tri-Clamp, Varivent and flange. Learn more about 11

12 Less Expensive PLC Connection Ring Topology for Reliability A new weight transmitter for PLC connectivity now includes two industrial Ethernet ports, which can be used to connect to a redundant-ring topology with PROFINET IO or EtherNet/IP. This provides even higher reliability and more efficient wiring as it does not require a switch when several devices are connected. The ACT350 weight transmitter for very fast and accurate weighing offers: 800 filtered-weight values per second to PLC System Display and keyboard for weight display and configuration Legal-for-trade accuracy of 6,000e OIML and 5,000d NTEP Dual-port PLC connectivity eliminates need for Ethernet switch Media Redundancy Protocol (MRP) standard for PROFINET Device Level Ring (DLR) standard for EtherNet/IP Watch our video about PLC connectivity METTLER TOLEDO Group Industrial Division Local contact: For more information Subject to technical changes 02/2018 METTLER TOLEDO. All rights reserved Document No MarCom Industrial