Aventics Smart Pneumatic Monitoring System

The fourth industrial revolution revolves around networking

What does the Industrial Internet of Things mean?

The Industrial Internet of Things refers to interlocking production with the latest information and communications technology while simultaneously integrating customers and business partners into business processes. Today, all participants in the complete value-added chain are principally able to exchange information thanks to the advanced technologies used for networking, intelligent components and workpieces – no matter whether it's workpieces communicating with tools via barcodes or RFID, a drive reporting its status in a production system or the operator’s maintenance control station communicating with the machine manufacturer’s spare parts service.

Information exchange between all players in the process: the three pillars of communication

People, products and processes: Communication between these three cornerstones is at the core of AVENTICS’ IoT strategy. People, machines and processes are all directly related.

People: The collection and analysis of data are easy to visualize, only relevant data are passed on to users and errors and malfunctions are reported directly.

Products: Each product is a part of the information chain, data are processed by local hubs, product data can be accessed locally and data transfer is standardized.

Processes: The entire value flow is analyzed with a focus on critical points and data, relevant products and systems autonomously exchange data and data that has a bearing on the target group is preselected automatically.

AVENTICS components are ready today for tomorrow’s networked systems

Future-proof system design

We combine know-how, application expertise and professional user experience – and offer a wide range of products ready for any digital demands. Connectivity and the ability to communicate have been an integral element of our components and systems and of AVENTICS' product policy. Your advantages:

Predictive maintenance through integrated diagnostics
Energy efficiency through effective use of compressed air
Operating comfort thanks to simple plug-and-play application

Compatibility and durability

AVENTICS smart components integrate seamlessly into a digital environment thanks to on-board intelligence and compliance with all relevant communication standards. Our solutions focus on the flexible further use of the generated information. Local evaluation and storage in the component, in a local database, in a private or public cloud – all options are covered.

Plant installers often rely on components from various suppliers. This is why AVENTICS consciously focuses on cooperation with other manufacturers. “The Internet of Things also means machine and automation suppliers are linked,” emphasises Paul Cleaver. AVENTICS works with numerous other companies to develop complete solutions that create major added value for customers.

Smart Pneumatics Monitor (SPM) – our core product for digital process networking

Want to check the state of wear? Need information on energy efficiency? The new Smart Pneumatics Monitor will provide you with reliable answers. It sends status messages to defined employees and parent IT systems without detouring to the machine controller. This minimises the risk of machine downtime and substantially lowers operating costs.

How it works: data flows

Together with our AES fieldbus solution, the Smart Pneumatics Monitor (SPM) IoT gateway analyses existing sensor signals and uses the result to generate reliable status information. To monitor the wear of a shock absorber, for example, the SPM breaks down the end switch signals to evaluate the cushioning sequence. Algorithms written by AVENTICS based on the company’s application experience analyse this data internally and send the information either to defined people or to the parent MES or ERP systems via the OPC UA interface.

Easy configuration and operation, major benefits

Using drag and drop, the components to be monitored are combined and linked in the SPM. On request, the module monitors the current energy consumption or the degree of wear, for example. Users can take measures for optimisation early on and thereby meet the requirements set out in the EU Energy Efficiency Directive as well as minimise unplanned system downtime.

1. Maintenance Monitor - Determining Wear

The shock absorber in this configuration had been replaced in regular routine intervals determined on the basis of past experience with the individual application – purely as a precautionary measure and not based on actual facts. The SPM now uses the cylinder sensor data to analyze the cushioning's timing characteristics. Because cushioning time decreases over the service life of the shock absorber, it provides direct proof of its state of wear. As soon as a critical value is reached, an error message can be output to exchange the shock absorber before it fails.

2. Data Management – Counting Switching Cycles

A valve's state of wear is very difficult to determine from the outside but additional internal sensors would increase its size and add to costs. In contrast, the SPM is able to provide information on the expected service life of the valves – without incurring additional costs and effort. By measuring the valve's exact switching cycles it is possible to extrapolate the end of its typical service life. Preventive maintenance can then be carried out to avoid downtimes in critical applications.

3. Energy Efficiency - Detecting Leakages

Energy efficiency is a key economic factor. The SPM gives a clear indication of where and how compressed air consumption changes – and allows users to determine the location of possible leakages. Predictive diagnostics is one of the main arguments for efficient use of the SPM.

4. Optimized Consumption - Creating Optimal Compressed Air Balance

Whether during initial configuration or to improve ongoing operation: An optimum compressed air level saves money and prevents wear on the components. An SPM analysis helps you to determine the optimal operating point for a perfect balanceof the work to be carried out and the supplied energy.