This information can also be used to develop concepts for predictive maintenance. The basis for this is the fast, efficient and comprehensive evaluation of analog and digital data - measured values, signals and operating parameters - by the intelligent PLC in the drive electronics.

The aim of predictive maintenance is to proactively maintain machines and systems and detect changes, reduce downtimes and increase overall system effectiveness. Condition-based maintenance replaces traditional time-based maintenance.

Unplanned downtimes or machine failures can be avoided by detecting and preventing unacceptable operating states at an early stage. Predictive maintenance enables predictable machine or system downtimes based on real drive and process data. For operators of systems and machines with drive systems from Nord Drivesystems, this results in a reduction in service and material costs and increased system availability. Other advantages include an increase in the service life of components and machines as well as predictable and cost-optimized maintenance.

Intelligent algorithms use drive data

Nord Drivesystems pursues a drive-based approach in which information from condition monitoring is transferred to predictive maintenance using intelligent algorithms and virtual sensors. This includes, for example, sensorless determination of the optimum oil change time based on the oil temperature. This makes use of the fact that oil ageing in gearboxes is particularly dependent on the oil temperature.

This information, in combination with known transmission parameters and specific, operational parameters, enables a more precise indication of the oil change time. A physical temperature sensor is not required for this. The drive data is pre-processed by intelligent algorithms in the integrated PLC of the frequency inverter, which serves as the evaluation unit. The data obtained can be made available via all common interfaces.

The right PLC software architecture for every solution

The drive's equipment can be optionally expanded and adapted to the respective automation task. The customer can choose which tasks (drive monitoring, drive control, process control) he wants to transfer directly to the drive. This scalability gives them the opportunity to gain initial experience in a smaller production area, for example, before converting their entire system.

Three expansion stages are available. In the small version, the drive PLC only monitors the drive. The drive parameters are pre-processed in the PLC and forwarded to the higher-level system controller, which is then responsible for drive and process control. In the medium configuration, the PLC also integrates the drive control and thus also executes drive-related functions. In the largest expansion stage, the inverter PLC completely replaces the higher-level system controller. In addition to communication with a control system, a local data management system without an internet connection can also take over the data if required.