Page 45 - MetalForming-Apr-2018-issue

Sensor Technology on the IoT Front Line
Connecting a press shop can seem like a task only for larger manufactur- ers. And, many metalformers already have reliable, yet aging, equipment on the shop floor that is not yet ready for the scrap heap.
So, how then does a metalformer remain competitive and at the same time bring IoT to their existing facility and equipment?
“Smart manufacturing starts at the sensors,” explains Balluff’s Healy. “Tra- ditional inductive-proximity and pho- toelectric sensors find increasing use for die protection, automation setups and a host of other applications. Press- es, for example, contain sensors that keep track of pressure and position, and help to maintain safe operation. Smart sensors bring a new level of pro- ductivity to the shop by providing device health status, diagnostics and warning events, supporting a proactive predictive-maintenance program that promises to reduce downtime.”
However, Healy warns that it doesn’t always make sense to have an Ethernet infrastructure for small amounts of data. In home-automation systems, for example, a smart light bulb or smart switch has only a few data points to communicate. These IoT devices typ- ically use an open standard to connect many smart devices to one Ethernet address.
Similarly, IO-Link is an open indus- trial solution supported by more than 120 automation suppliers. It connects smart sensors into a machine control while enabling IoT applications. “From these connections,” Healy says, “we can create historical records of events in the plant, generate analytics and gain views into production. Over time, we can develop troubleshooting tactics to reduce downtime events and execute a more targeted predictive-mainte- nance plan to, possibly, eliminate downtime completely.”
Illustrating use of IoT in metalform- ing operations, Healy points to Eagle Press & Equipment Co.’s implementa- tion of IO-Link as a simple platform
to allow smart sensors to communicate with an automation controller. Not only does the smart sensor report its measurement or switching data, but it also can communicate diagnostics and parameters.
“For example,” he says, “a pressure sensor’s parameters can be stored and redownloaded upon replacement or configuration change. This makes the service and maintenance of the press dramatically easier for the metalformer. With IO-Link, if there’s a service or war- ranty call, it is much easier to fix a cable or device on the press to get the machine running again. And, since IO- Link provides device parameter storage, the press can even tell the customer if it installed the wrong part number on replacement.”
Eagle Press has seamlessly integrat- ed pressure, level and temperature smart sensors in a variety of applica- tions on the press, including the lube, clutch and bolster control to monitor hydraulic fluid level, pressure and tem-
perature. Additional smart sensors can provide control of the scrap-chute door, counterbalance and hydraulic-overload circuit. Likewise, an IO-Link linear posi- tion sensor can measure shut height. In the end, all of these IO-Link devices across the machine enable it for IoT applications.
Healy’s final thoughts concern adding IoT capabilities to existing equipment.
“The most successful implementa- tions,” he says, “start with an obvious but often-overlooked realization that the project must provide ROI. So, start by forming a cross-departmental team, which includes IT, and discuss prob- lems in the plant. Identify a trouble- making machine, or perhaps operators who are struggling to locate tooling in a timely manner. Focus on problems that hinder production efficiency, cre- ate an unreasonable level of mainte- nance or result from operator errors. These issues will serve as perfect pilot projects for IoT.” MF
Fabrication: IoT
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