Nick Roseto ABB Motors and Mechanical Key Account Manager Mining, - - PowerPoint PPT Presentation
Key Stats Reside Chicago, IL 25 year industry experience Sales & Engineering background Univ. of Illinois Bachelor of Engineering Purdue University Master of Engineering Slogan I am here to
FEBRUARY 2018 – INDUSTRY 4.0 – DIGITAL SOLUTIONS IN AGGREGATES
Key Account Manager – Mining, Aggregate and Cement Industries
Key Stats
The digital revolution – coming now to industrial markets The digital platform – Industry 4.0 The digital powertrain Applications in aggregates Changing the paradigm Types of digital solutions available Digital solutions in action Considering the bottom line Summary
Agenda
— The digital revolution
The operation of business has changed and will certainly continue
Media is focused on B2C but the “killer app” is in B2B
Digital technologies are driving new innovation in industrial markets
Virtual/augmented reality Software-defined machines Machine learning Time-sensitive networking Big data Inexpensive computing Cloud computing Cybersecurity Connectivity Blockchain
Global trend – Fourth Industrial Revolution
The Internet of Things (IoT)
Industry 1.0 – 1712 First practical steam engine Industry 2.0 – 1870 First elevated conveyor belts Industry 3.0 – 1969 Electronics / software based control
Connect your assets to digitally perform and extend service life
Services Things People
Industry 4.0 – today and tomorrow Internet of …
A $4 – 11 trillion digital opportunity by 2025 (productivity or cost reductions)
Economic value migration opportunity
Range of sized potential economic impact Low High
Disruptive technologies will have substantial impact by 2025 (economic impact of 12 most significant technologies, $ trillions, annual)
3.9 – 11.1 3.7 – 10.8 5.2 – 6.7 1.7 – 6.2 1.7 – 4.5 0.2 – 1.9 0.7 – 1.6 0.1 – 0.6 0.2 – 0.6 0.2 – 0.5 0.1 – 05. 0.2 – 0.3 Internet of Things Mobile internet Automation of knowledge work Cloud technology Advanced robotics Autonomous and near-autonomous vehicles Next-generations genomics Energy storage 3D printing Advanced materials Advanced Oil & Gas exploration and recovery Renewable energy
1 2 3 4 5 6 7 8 9 1 1 1 1 2
Computing + connectivity + cloud + analytics set to unlock value
Industrial markets primed to adopt digital technologies
Time
Digital S-Curve
Level of digitalization
ABB end-market Other industries
Not “business as usual”
Accelerating rate of change: new entrants
42 22 10 20 30 40 50 2009 2015 Median Age of new entrants to the S&P 500
Closing the loop – producing, analyzing and acting on data
What does it take to win in digital?
From physical to digital differentiation
Maintenance Operation Control
Service action Set points Control signals Plant / equip. health Operational data Measurements
— The digital platform
Connecting users to their machine
The digital platform
Customers
Digital Ability:
Digitally connected products & services
Uptime Speed Yield Safety Security
Expertise
Information Technology Know-how
Digital solutions built on a common set of standard technologies
Unlocking the potential in digital
Open access, intelligent cloud Closing the loop with connected devices New end-to-end digital solutions Systems to master process control
Digital solutions & platform
Digital Ability
Provides efficiency and scale Delivers customer benefit (uptime, speed, yield…) What How Platform
(common technologies for device, edge, and cloud) Utilities solutions Industry solutions Transport & Infrastructure solutions
Suppliers x system integrators x developers x 3rd party apps = user leverage
Benefits of an industry-standard platform
IT innovations + OT expertise Developers System integrators Core platform
Thousands of application needs available
Innovation takes ability
Utilities Industry Transportation & Infrastructure
Improved productivity (>200%), reduced energy (<30%), & longer product life (<30%)
Industry
SELECTION
Connected robots Manufacturing execution systems Energy assessment Cybersecurity assessment Digital simulation for robot deployment Power quality monitoring & demand-response Distributed control systems Remote monitoring &
Proactive detection of faults (<90%), reduced maintenance costs (<20%) and energy costs (<5%)
Transport & Infrastructure
EV charging with cloud management Flash-charging electric buses Energy management for mega-datacenters Remote monitoring for ship electrical systems Building automation Vehicle-to-grid demand/supply coordination Navigation optimization for fleets
Digitally connected products and services providing expertise
Digital solutions deliver value
Do more Automate
Act
Do better Optimize Assess Know more
Analyze Sense
Digitally connected products and services providing expertise
Digital solutions deliver value
Know more Do more Do better Together Assess Automate Optimize Collaborate
Analyze Act Sense Analyze Act Sense Analyze Act Sense Analyze Act Sense
On-premise, in the cloud, and in an ecosystem
Leveraging the digital platform
Fog Cloud Intercloud
Edge Device Cloud Edge Device
Lumada Predix Mindsphere Ecostruxure Digital Ability
Making solutions and data safe for mission-critical applications
Digital ability: security, data, and IP
What is your IoT data manifesto? What is your intellectual property position? What are your cybersecurity standards?
Secure your systems:
Secure operations Threat detection Secure communications Secure updates Secure boot
You own your data:
Identity Measurement data You know what we do with your data We only share data with your consent
You own your IP:
No loss of intellectual property when using Digital Ability solutions
𝑔(x)=$
— The digital powertrain
Connecting users to their machine
What is the Digital Powertrain?
An intelligent powertrain, equipped with sensors and cloud connectivity, comprises motors, drives, mechanical components including bearings, couplings and gearboxes, and applications like pumps, fans and compressors.
be a game-changer
It’s not about fancy graphs
Digital Powertrain: The client’s perspective
It’s about saving money
Digital Powertrain: The client’s perspective
Types of digital powertrain connectivity
Low End connector solutions High End connector solutions
Scalable solution on site, and 1 unique portal, end customers and OEMs
An expert or the end customer log in RCM portal, check KPIs calculated with data coming from:
Low and high end connected solutions
Digital powertrain process flow chart for end users
Digital advantage delivered through the digital powertrain
MOUNTED BEARINGS MOTOR OR GENERATOR DRIVE OR CONVERTER TRANSFORMER CUSTOMER APPLICATION / PUMP
A digital advantage that accelerates efficiency, predictability and safety
Cloud Digital Powertrain
— Applications in aggregates
Primary focus integral to all quarries, sand and asphalt production
Process map – conveying, crushing, screening, and pumping
Aggregates in action
Conveying
Aggregate application
Conveyor applications: moving rocks between processes
Application requirements
Severe duty High efficiency Normal and high torque designs Torque multiplication Mounted bearings Pulleys and shafting
Motors, gear reducers, pulleys, bearings
Overland Stackers Blending Load out (Barge/ Rail/ Truck)
Aggregate application
Crushing
Crusher applications: making little rocks out of big rocks
Application requirements
High torque design Belt driven Roller bearings/ belted duty Severe duty and vibration Variable speed operation
Motors, variable frequency drives, belt drives
Jaw Crushers Cone Crushers Horizontal or Vertical Shaft Impactors Hammer Mill
Aggregate application
Screening & Classifying
Screening applications: separating size ranges
Application requirements
Typical inclined screen
Severe duty and vibration High efficiency Variable speed operation High torque design Above normal service factor Roller bearings / belted duty
Motors, belt drives
Wire screen cloth
Pumping
Aggregate market
Pumping applications: processing and circulating water
Application requirements
Severe duty Premium efficiency VFD operation Normal torque designs Normal service factor Coupled duty or belted duty
Motors, variable frequency drives
Dewatering Storm water control Washing Sediment removal
— Changing the paradigm
Maintenance versus service life of product
Equipment failures
Electric motors
51% 16% 16% 5% 2% 10%
Bearings Windings External Factors Rotor Bar Shaft/Coupling Unknown
51%
– Bearing failures cause 51% of motor failures – Preventative mechanical maintenance
Equipment duty classification
Electric service condition = severe Service Condition Ambient Temp Bearing Load Atmosphere Operating HRS. per Day Standard
Steady Clean 8 Severe
(1) Medium Shock Vibration (<0.2 in/sec) Medium Dirt Abrasives Corrosion 8 to 24 Extreme
(1) Heavy Shock Vibration (<.44 in/sec) Heavy Dirt Abrasive Corrosion 8 to 24
Lubrication frequency
Electric motors Speed Frame Standard Severe Extreme =<1800 182-215 3 years 1 year 6 months =<1800 254-365 2 years 9 months 3 months =<1800 404-449 1 year 6 months 3 months =>3600 All 6 months 3 months 1 month
Equipment failures
Mounted Bearings – 80% of premature bearing failures are due to lubrication – Preventative mechanical maintenance
80% 10% 9% 1% Lubrication Installation Wrong bearing Mfg defects 5% 15% 20% 20% 20% Liquid contamination Insufficient lubricant Solid contamination Aged lubricant Wrong lubricant
Modes of failure
Mounted Bearings
Lubrication frequency
Mounted bearings
Lubrication Guide – suggested lubrication period in weeks
Hours Run Per Day 1 to 250 RPM 251 to 500 RPM 501 to 750 RPM 751 to 1000 RPM 1001 to 1500 RPM 1501 to 2000 RPM 2001 to 2500 RPM 2501 to 3000 RPM 8 12 12 10 7 5 4 3 2 16 12 7 5 4 2 2 2 1 24 10 5 3 2 1 1 1 1 Typical of aggregate industry applications
— Types of digital solutions available
How do these devices work?
System layout
Digital Smart Sensor
Cloud Services Customer Site
Cloud-based platform and User portal Customer portal Customer
Sensors
Gateway
– Cloud-based data trend storage and backup – Increased sensor battery life time – Perfect solution for location where H&S rules do not allow using hand held devices – On-line monitoring several sensors in gateway range – Continuous monitoring of critical applications – Remotely adjust alarms based on data trends – Quick overview of the site assets health status – Easy assets performance comparison
Digital Smart Sensor
Connecting multiple devices - Gateway
Cloud Gateway
– Significant installed base – Bearing is a critical component of the overall system, industrial fan, conveyors, processing equipment, etc. – Monitoring of the bearing is a standard maintenance practice – Bearing is the first indicator of potential system problems
Smart sensor for mounted bearings
Mounted bearings have a finite life
– Wireless communication – Bluetooth – Measures vibration and temperature – Advanced algorithms for bearing diagnostics – On board storage: 30 days data storage – Connection to common platform – Software: Android & iOS
Smart sensor for mounted bearings
Sensor particulars
– Visual diagnostic of asset without physically looking at it – Warnings on decreasing assets health status – Ability to properly analyze why a bearing failed – Continuously collect reliable data to central storage – Ability to reduce downtime – Ability to reduce unplanned, unscheduled maintenance – Easy installation – Small investment to prolong application availability
Smart sensor for mounted bearings
Customer benefits
Digital portal – mounted bearings
Central storage of information
Smart sensor for electric motors
Smart sensor
A sensor is like a fitness wristband for electric motors. Fit it easily to the surface of a motor, without wiring or machining, and collect operational data and health info
Maintenance and operation can be optimised in a way that was not possible before. The benefits can be huge, payback time expected to be less than one year in most cases. With IoT-technology the sensor does things at a low cost that was unthinkable a few years ago.
Basis of installation
Smart sensor for electric motors
UNF 1/4"- 28 as mechanical interface. “Future proof" for possible upcoming Smart Sensor of different design. The sensor mount is permanently installed on the motor using adhesive putty (Henkel Loctite 3463). 6 sizes of sensor mount are available initially.
Low Energy
Built-in batteries (Not user exchangeable.) Firmware with FOTA (Firmware Over-The-Air, i.e. updates via smartphone) Initial certification logos: CE, Bluetooth, UL, FCC, WEEE "Wheelie"
Range:
> 100 m
~ 50 m
< 25 m
MEMS Multi-Sensor System inside No electrical wiring required / possible.
What does it monitor?
Smart sensor for electric motors
Parameters supported Problem or operating characteristic Release Overall Vibration Unbalance, loose mass, coupling management, load effects, soft foot, etc. Axial Vibration Radial Vibration Tangential Vibration Bearing Condition Bearing damage Cooling Condition Overheating due to blocking of air flow Airgap Eccentricity Soft foot/bent shaft/thermal bow Rotor Winding Health Cracked rotor bar/ring detection Skin Temperature/ °C or °F Operating information Energy Consumption/kWh Process change, replacement decision Operating Hours/h Operating information Operating Power/HP Process change, reliability (overloading) Number of Starts Operating information Speed/rpm Operating information Motor Supply Frequency/Hz Operating information Notifications Re-greasing Advice Battery indicator
First release - Future release - □ Covered motor types (First release): – Standard 3-phase LV induction motors – Rib-cooled frame, TEFC – 140-440 NEMA, 160-450 IEC frames – Safe area – S1 duty – Fixed Frequency, Low Dynamic VFD Many other types and duties will become available during 2018.
Health Parameters are provided with latest reading and color coded indication
Latest operating parameters are provided
Operational and Health Parameters
Features of the APP
App provides notifications about certain parameters Select “Take action” and log what maintenance action was performed to address the issue Then a history is kept of all maintenance actions taken
Built in Maintenance log
Features of the APP
Motor nameplate data is readily available and easy to read Sensor information is available to ensues the most up to date version is being used.
Nameplate and Sensor Data
Features of the APP
Organization Overview
Web portal dashboard – electric motors
Bearing Condition
Web portal – case study on electric motors
Vibration Case Study
Web portal – case study on electric motors
Using similar sensors for multiple components
Smart sensor for pump applications
Pump Parameters
Starts
Condition
Common failure modes of idler rollers
Digital solutions for conveyors
Failure Modes
Monitoring the idlers
Digital solutions for conveyors
A crawling robot for larger motors with air gap over 10 mm
Digital solutions for large motors for air gap eccentricity
Know the health of your critical assets
Digital solutions for transformers
Organization
Organizational Management
Control who can see what assets for added security and efficient maintenance.
Asset Group 1 Asset Group 2 Asset Groups User Group User Group 1 User Group 3 User Group 2 Organization ABC
— Digital solutions in action
Pictures of digital solutions in action
Customer test sites
Application – centrifugal fan Bearings – P4B-IP-307R, RE Continuous data through gateway
Fan OEM
Customer test sites
Application – Primary Crusher Tail pulley – P4B526-TAF-407R, RE Data pull via Mobile Phone
Quarry
Customer test sites
Quarry
Customer test sites
Application – washing, sorting Bearings – P4B-DI-407R, RE Data pull via Mobile Phone
Quarry
Customer test sites
Application – Plenum fan Bearings – P2B-IP-111LE, P2B-DL-111 Continuous data pull via gateway
Fan OEM
Customer test site
Application – Troughing Mixer Application Trunnion Wheel Data pull via mobile phone
Mixer, Dryer
Customer test sites
Things to think about at your location
Important considerations
‒ Availability of cell service ‒ Bluetooth range can exceed 60 feet without obstacles ‒ Know your company’s IT policies ‒ Who will have access to the sensor data and portal ‒ Will you allow your supplier to have access to your sensor data? ‒ Consider use of a gateway for continuous data monitoring ‒ Consider applications that are choke points, or primary ‒ Monitoring a system and not just a bearing
— Considering the bottom line
What is your downtime worth?
– Revenue (sales) – Cost of goods sold – Gross profit – Operating costs (overhead) – Net profit before tax – Tax – Net income (profit)
Profitability
Digital technology improving the bottom line $140,000,000 ($ 91,000,000) $ 49,000,000 ($ 38,000,000) $ 11,000,000 ($ 4,000,000) $ 7,000,000
The digital revolution and platform The digital powertrain Applications in aggregate Changing the maintenance paradigm Types of digital solutions available Considering the bottom line
Summary
Using connected digital solutions to deliver expertise for customer value
Future blueprint for digital solutions
Integrated Connected Supported Data-driven Physical + Digital Flexible Secured & Trusted Expertise