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AI-based Predictive Service Assistance
for Drive Systems saves costs on the first day
Metals
Aperam
Genk Belgium
Aperam has two critical dedusting fans in its production. When they are in standstill, the entire production line needs to be stopped, which is very expensive. To optimize productivity, Aperam is looking for:
Transparency
for the assets
conditions to prevent unplanned downtimes
Timely recognition of potential faults and execution of counter measures during standard maintenance intervals
Siemens service experts proposed a complete solution based on the Predictive Services for Drive Systems approach. First an assessment was performed to look for the bottlenecks and possibilities on the existing installation.
After the assessment the experts connected the motor and frequency converter to MindSphere. On the motor (third party), Simotics Connect 400 was installed to monitor motor vibrations, current and speed. The frequency converters (SIMATIC S120 cabinet modules) were connected via MindConnect Nano. This module transfers the most important parameters, such as currents, temperatures and alarms, to MindSphere.
The information from both - motors and frequency drives - is evaluated in the MindSphere application Predictive Service Assistance. This application monitors the health status of the drive train and launches the appropriate actions when a problem is detected. Additionally, the application also provides transparency on maintenance planning, product lifecycle and spare parts.
This digital platform is combined with a service contract: Siemens drive experts regularly check the data to make deeper interpretations and provide context to the customer.
The setup proved its value on the first day: The Predictive Service Assistance application triggered an alarm, which indicated a dangerous evolution of the frequency converter temperature. Since the problem was still at an early stage, the drive did not yet give an alarm.
Our drive experts investigated the problem and quickly found a problem with a cooling fan in the frequency converter. The problem was not yet critical, but would soon be. Based on the information in the app, the customer and Siemens were able to schedule the ideal moment for an intervention.
Without Predictive Service Assistance, the failure would have led to additional (estimated) repair costs of 15,000 euros and a (estimated) shutdown cost of more than 10,000 euros.
The Aperam group is a multinational producer of stainless steel. The plant in Genk has a steel factory and a cold rolling mill. There work more than 1000 people on the Genk plant alone.
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