Bosch Rexroth. The Drive & Control Company

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1 osch Rexroth. The Drive & Control Company Optimized Uptime and proactive Maintenance provided by osch Rexroth Stefan Saul Director Product Management Global Services, osch Rexroth 1

2 Agenda A C Life Cycle Costs & Maintenance Philosophies Condition Monitoring preventive to predictive maintenance Optimized Uptime structured maintenance management offers 2

3 Maintenance Philosophies (Result of the end user needs analysis) A Main parameters for the choice of the maintenance philosophy: Cost of downtime Current degree of caution employed by the end user reactive Maintenance philosophy proactive 3

4 Service Products for different Maintenance Philosophies Added value Extended Warranty Standby Agreement Availability Guarantee A Machine Service Manual Spare Parts Management Agreement Life Cycle Management Services for Locks and Weirs Condition Monitoring Risk Analyses Exchange of Components Oil Treatment with VacuClean Service for Energy Cylinder Predictive Maintenance Agreement Performance ased Maintenance Trouble-shooting Oil Analyses Preventive Maintenance Agreement Predictive Maintenance Repair Fitness Check Preventive Maintenance Spare Parts asic Maintenance Failure ased Maintenance Maturity level of maintenance 4

5 Agenda A C Life Cycle Costs & Maintenance Philosophies Condition Monitoring preventive to predictive maintenance Optimized Uptime structured maintenance management offers 5

6 Advanced Data Analytics for Predictive Maintenance in Industrial Applications 6

7 Condition Rexroth Drive & Control Systems Customer requirements: TCO reduction Reduced unplanned downtime Risk minimization etter component lifetime utilization Maintenance optimization (preventive predictive) Easy Handling 7

8 Challenges Mechanical components Very few sensors preinstalled Dynamic Operations Individual machine behavior Sensors with analog output (+/- 10V, 4 20 ma) Remote locations Environment: noise, vibrations, dust, temperature, oil, corrosion No reference data, theoretical models not applicable (too many unknown parameters) 8

9 System Architecture ODiN Condition Monitoring Data Acquisition Service Agreements Rexroth Services Rexroth Service Portal Predictive Analytics Status Reports 9

10 Advanced Data Analytics for Predictive Maintenance in Industrial Applications ig Data Machine Learning Large Volumes of Data Collected from Diverse Sources at High Speed Algorithms making predictions based on input data 10

11 Example: Conveyor elt (Mining) Pilot Application (ulk Material Handling) Conveyor elt: 3 Rexroth Systems (Motor + Power Units) 24/7 Operation Downtime cost = /hour Customer is interested in the health state of his machine, not in signal analysis Missing maintenance capacity Missing own know-how 11

12 Maximum Equipment Availibility throughout the entire lifecycle ODiN Condition Monitoring Traditional signal analysis ODiN Machine Health Index (MHI) ODiN Advantages: Data Mining (ODiN) approach improves quality of predictive forecasting significantly Complex machine behaviour represented in a single graph No need for manual threshold setting Significantly reduced number of false alarms One engineer can monitor a larger number of applications 12 18/2/2015 Dr. Tapio Torikka DC-IA/SVI osch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as

13 Data Mining-based Failure Detection Confirmed Nothing can be observed under manual evaluation of signals before E-motor current drops to zero (June 15 th ). E-Motor Failure Abnormal behaviour Put machine under intense observation Time

14 ODiN Predictive Maintenance Service Reduction of the risks associated with unplanned downtime Automatic Calculation of Machine Health State Analysis with Data Mining / Machine learning combined with big product-know-how No need to manually analyze signals Maintenance Recommendations by Rexroth Experts Rexroth offers 3 years Predictive Service Package with an annual fee, including: Status analysis (Health Check) Sensors & Data Acquisition (where required) Data Transmission, Storage, Analysis & Report (Maintenance Recommendations) Maintenance Agreement 14

15 Agenda A C Life Cycle Costs & Maintenance Philosophies Condition Monitoring preventive to predictive maintenance Optimized Uptime structured maintenance management offers 15

16 Maximum Equipment Availibility throughout the entire lifecycle Predefined, industry specific & customizable service packages to maximize system availability and minimize total cost of ownership What we offer Competent inspection of hydraulic drive system carried out by trained service personnel D Predefined scope of work according to manufacturer recommondation (360 degree inspection) Optimal power and reliability ensured through the use of original spare parts Identification of sources of problems, such as wear and defects Recommondations for maintenance measures 16

17 Remote Condition Monitoring - a key enabler for Predictive Maintenance Services Predefined, industry specific & customizable service packages to maximize system availability and minimize total cost of ownership Thank you for your attention! 17

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