FEBRUARY 2018 – INDUSTRY 4.0 – DIGITAL SOLUTIONS IN AGGREGATES
Nick Roseto – ABB Motors and MechanicalKey Account Manager – Mining, Aggregate and Cement Industries
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 help.”
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 revolutionThe 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
ThingsPeople
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
01
11
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
0
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 platformConnecting users to their machine
The digital platform
CustomersDigital 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
HowPlatform
(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
180+ digital solutions
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 &
optimization
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 AutomateAct
Do better Optimize
AssessKnow more
Analyze
Sense
Digitally connected products and services providing expertise
Digital solutions deliver value
Know more
Do more
Do better
Together
Assess
Automate
Optimize
CollaborateAnalyze
ActSense
Analyze
ActSense
Analyze
ActSense
Analyze
ActSense
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
𝑓(x)=$
—
The digital powertrainConnecting 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.
• For a client it is not important if a motor or a drive has a problem; it is about the availability of the application
• Combining information from different components allows for better predictions on the connected behavior
• Partnering with pump, compressor and fan manufacturers allows for increased value to the end-client
• Today, more than 80% of powertrains are not monitored. Therefore providing a simple, cost-efficient solution will
be a game-changer
• Providing advanced services at the click of a button enhances the experience and efficiency
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
• Remote Condition Monitoring and Assistance
• Predictive maintenance
• On site condition Monitoring
• High data traffic for Analytics
• Multi device, to cloud Communication
• OEMs Cloud Data Sharing
• 1 internet access per site
• Possible use customer network
• Remote Condition Monitoring and Assistance
• Installation cost optimized
• 1 internet access per device
• Or Bluetooth gateway
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 aggregatesPrimary 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 applicationCrushing
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 applicationScreening & 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 paradigmMaintenance versus service life of product
Equipment failuresElectric 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
• Greasing bearings
• Cleaning surfaces
• Verify load connection (couplings/belts)
Equipment duty classificationElectric service condition = severe
Service
ConditionAmbient Temp Bearing Load Atmosphere
Operating HRS.
per Day
Standard -18C to 40C Steady Clean 8
Severe-30C to 50C
(1)
Medium Shock
Vibration (<0.2
in/sec)
Medium Dirt
Abrasives
Corrosion
8 to 24
Extreme-54C to 65C
(1)
Heavy
Shock Vibration
(<.44 in/sec)
Heavy Dirt
Abrasive
Corrosion
8 to 24
Lubrication frequencyElectric 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 failuresMounted Bearings
– 80% of premature bearing failures are due to lubrication
– Preventative mechanical maintenance
• Follow manufacturers guidelines
• NLGI #2 lithium base grease
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 failureMounted Bearings
Lubrication frequencyMounted 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 availableHow do these devices work?
System layout
Digital Smart Sensor
Cloud Services
Customer Site
Cloud-based platform and User portal
Customer portalCustomer
or engineer
Sensors
on motors
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 SensorConnecting 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 bearingsMounted 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 bearingsSensor 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 bearingsCustomer benefits
Digital portal – mounted bearingsCentral storage of information
Smart sensor for electric motorsSmart sensor
• Safety - Improve safety at work with maintenance inspections from a distance
• Reliability – Reduce downtime with a transition from reactive to proactive maintenance
• Energy Savings - Save energy with proper sizing of motors
• Maintenance Savings - Save time and effort of maintenance engineers with early warning systems
• Net Working Capital – Equipment can live longer with less redundant plant and inventory
• Risk Mitigation – Minimise your liabilities, such as warranty, uptime guarantee, transportation, etc.
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
of the motor.
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:
- theoretical max: > 100 m
- realistic: ~ 50 m
- industrial environment: < 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
• Red- Critical
• Yellow- Alert
• Green- Healthy
Latest operating parameters
are provided
Operational and Health ParametersFeatures 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
on that motor
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
• Vibration
• Temperature
• Number of
Starts
• Operating Hours
• Bearing
Condition
• Blade Imbalance
• Cavitation
• Unbalance
• Flow Turbulence
Common failure modes of idler rollers
Digital solutions for conveyors
Failure Modes
• Damaged bearings
• Worn shells
• Tracking problems
• Operating Hours
• Blown ends
• Temperature issues
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 ManagementControl 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 actionPictures 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 sitesQuarry
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 sitesThings 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 lineWhat is your downtime worth?
– Revenue (sales)
– Cost of goods sold
– Gross profit
– Operating costs (overhead)
– Net profit before tax
– Tax
– Net income (profit)
ProfitabilityDigital 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
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