Focus on: Smart Maintenance Maintenance Matters maintenance uses operational data to identify developing problems before they stop production. Engineers can compare how a machine behaves over time. A drive that needs more current for the same movement, a gearbox that is running hotter than normal, or a fan that shows increasing vibration can all suggest that equipment is beginning to deteriorate. Instead of discovering a worn bearing after a breakdown, manufacturers can spot gradual changes in performance, schedule maintenance during planned shutdowns and avoid unexpected production losses altogether. The result is not only greater reliability but also improved energy efficiency, as machines operating within their intended parameters typically consume less power than poorly performing equipment. AI turns data into decisions The challenge for many manufacturers is no longer collecting data. Modern factories generate enormous volumes of information every second. Now, it’s about how to make sense of it. Artificial intelligence is increasingly becoming the link between raw industrial data and practical decision-making. Rather than engineers manually reviewing thousands of measurements, machine learning algorithms can identify patterns across energy use, compressed air demand, temperatures, vibration, motion profiles and production performance. Those insights help manufacturers understand relationships that would otherwise remain hidden and create increasingly accurate predictions of future performance. Looking ahead, manufacturers will move towards creating a digital profile for every machine. By combining operational history with live analytics, each asset will effectively develop its own performance passport, allowing operators to understand exactly how it should run for maximum efficiency, product quality and minimum energy consumption. Visibility drives efficiency While sustainability targets and environmental reporting continue to influence investment, commercial pressures remain the primary driver for many manufacturers. Rising energy prices have made efficiency impossible to ignore. The companies that gain the greatest advantage will not necessarily be those investing in entirely new equipment. Instead, they will be those extracting more value from the machines they already have by understanding how they perform in real time. Energy analytics provides that visibility. Once manufacturers know where energy is being used, why consumption changes and how operational decisions affect efficiency, they can make improvements that reduce costs, improve reliability and support long-term sustainability. As manufacturers continue to balance rising energy costs with productivity and sustainability targets, data will become one of their most valuable assets. By combining realtime analytics with intelligent automation, manufacturers can uncover hidden inefficiencies, make better operational decisions and reduce energy consumption without compromising output. For further information please visit: www.beckhoff.com Turck Banner Ltd. Blenheim House, Blenheim Court, Wickford, Essex SS11 8YT Tel: 01268 578888 wireless@turckbanner.co.uk Wireless Vibration & Temperature Monitoring As simple as your check engine light Distribute Connected data solutions • Data is pulled from the controller via cellular or Ethernet and Stored in a SCADA or Cloud Platform Alert and Consumption Consume the data via Dashboards, alerts and long term analysis • Early detection of any increase allows for planned, preventative maintenance Measure & Collect Wireless Vibration, Temperature & Current Monitoring • IP67 & IP69K Sensors • Sensors Powered by batteries Transmit IIOT Gateway/Controller Solution Kits • Sensors send data wirelessly to Gateway/Controller • Machine Learning Algorithm
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