AS-Interface communicates the device and diagnostic data directly with host systems and cloud solutions. © AS-International Association

As mentioned, the path to efficiency with predictive maintenance measures leads via the freely accessible diagnostic data, whereby two types of diagnostics must be considered: process diagnostics on the one hand and system diagnostics on the other. Process diagnostics monitors the machine or system process, i.e. the quality of the work carried out in the system or machine. The machine or system operator receives the corresponding diagnostic information from the sensors implemented in the process, i.e. positions, temperatures and pressures.

The system diagnostics provide information about the condition of the machine, whereby the diagnostic data from the devices is of particular interest. Users draw information from the device diagnostics, such as switching cycles, wear of materials subject to wear and lens opacity. Channel diagnostics, which is part of system diagnostics, is the reference for far-reaching predictive maintenance. It provides data on signal quality and provides information on communication errors and communication quality.

Ensuring duct diagnostics

The new ASi-5 technology from AS-Interface offers exactly this channel diagnosis. This means that the communication channel via which the devices communicate is permanently monitored and errors are logged. Normally, the operator does not notice anything. In the event of isolated faults, the system automatically switches to better communication channels and communication remains guaranteed. In special cases, for example if the earthing of a nearby EMC protective device corrodes and there is an increase in faults, the fault logs can be evaluated. This means that it is possible to react in good time before a system failure occurs, before major damage can occur or the machine comes to a standstill.

ASi-5 technology uses a separate communication channel for device diagnostics, the so-called acyclic services. This provides the devices with a communication channel with which diagnostic data can be forwarded "on event" or regularly scheduled at any time. The cyclical production process, in turn, remains unaffected and can continue to run smoothly.

Real Time Condition Monitoring

All diagnostic data for predictive maintenance can be mapped directly in the host system. Modern systems transfer the data to a cloud so that they are networked and the data can be used optimally. It is important that the diagnostic data is available so that the user is warned in good time. This allows service calls to be planned and spare parts management also benefits from this data. The evaluation of the data for "Real Time Condition Monitoring" is thus ensured at all times. The new ASi-5 technology provides the ideal basis for easily available diagnostic data. Predictive maintenance begins with the linking of these diagnostic elements.