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Predictive Intelligence for Pneumatics

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HOW IT WORKS

WELCOME TOTM2.0PNEUMATICS

Introducing IntelliSense®, a one-of-a-kind technology platform combining sensors, Bimba cylinders and software to deliver real-time performance data for standard pneumatic devices. With IntelliSense®, users can utilize condition-based monitoring to be proactive about maintenance and system optimization to maximize uptime in the age of full-tilt manufacturing.

The “intelligence” lies within the IntelliSense® Sensor Interface Module (SIM). This remote monitoring device gives users operational insights at the device level.

The IntelliSense® SIM can be easily connected to Bimba cylinders using pneumatic fittings.

Using a sensor pair, IntelliSense® is able to report a range of data, including cylinder condition, stroke time, end of travel, pressure and temperature.

Data and insights can be sent from the IntelliSense® SIM to a PLC for advance alarming and controls while also sending real-time information to a PC or IntelliSense® Data Gateway, which enables remote monitoring and data logging for user analysis.

The machine-to-machine technologies allow for close monitoring of individual components, giving users the insight needed to move from emergency repair to proactive maintenance––optimizing production as a whole.

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INTELLISENSE® DATA GATEWAY

• Remote monitoring for up to 12 SIMs• Ethernet and wireless connectivity• Data logging capabilities with 100+

GB of storage• Includes IntelliSense® Data Gateway

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REAL-TIME INSIGHTS FOR REAL RESULTS

INTELLISENSE® FOR ALL

With a constant influx of precise and accurate performance-related data, IntelliSense® helpsusers make smarter decisions to ensure maximum uptime and component performance.

Every day, users from a wide range of industries are finding new and exciting solutions toautomation’s most complex questions with IntelliSense®.

Predictive PrognosticsUp-to-date condition information allows IntelliSense® to predict when a cylinder will fail––increasing uptime.

Remote MonitoringUsing a network of smart devices, users can collect data and monitor machinery remotely, even from multiple locations.

Machine EfficiencyWith real-time data, users can identify whether a component is achieving its desired performance specification. This is especially important in sequencing applications that rely on precise stroke rates.

Maximizing ProductionFor customers running machinery 24/7 or producing large value batches, IntelliSense® can alert users to under-performing components––enabling proactive responses for maximum uptime.

In a world where C-level executives are pushing manufacturing to maximize throughput while maintaining superior quality measures, IntelliSense® provides the competitive edge. Optimize your productivity and efficiency in the new age of pneumatics with IntelliSense®. Find out more at bimba.com/smarter.

Cylinder StatusAccess the following data from your IntelliSense® SIM anytime, anywhere:• Cycle time• Cycle count• Estimated cycles remaining• Estimated days of life remaining• Estimated percentages of cylinder life remaining

Pressure and Temperature MonitoringEnsure efficiency and optimize air usage with up-to-date:• Pressure data every millisecond • Temperature data every second

IntelliSense® Data Gateway Data LoggingWith over 100GB of available storage, the IntelliSense® Data Gateway stores 20 different variables including:• Pressure• Temperature• Extend time• Retract time

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Maintenance Strategies for Pneumatic ActuatorsCourtesy of Bimba

Abstract:

An analysis of the different maintenance strategies for pneumatic actuators and the role sensors can play in each

When to use: A corrective maintenance strategy is effective when the cost of component failure is lower than the cost required to replace the component. To justify the application of a corrective maintenance strategy, all costs must be reviewed. These include: cost of component, value of downtime, labor hours, equipment location, availability of components, and cost of inventory.

Role of sensors:Corrective maintenance strategies rarely include sensors. Their addition increases the initial cost of the equipment. But, there are two ways that sensors can support a corrective maintenance strategy: as a diagnostic tool and as an indicator of a failure.

The most economical way to use diagnostic sensors is by installing them after a component fails. Once the sensor discovers the error, the sensor can be removed. This approach reduces startup costs because one set of sensors can work in multiple places, such as complex pneumatic circuits where symptoms of failure can go unnoticed.

A corrective maintenance strategy can also be enhanced with “intelligent” sensors capable of remote monitoring and alarming. A sensor that sounds an alarm when the system is not working can simplify maintenance, especially for difficult-to-reach locations. Without visiting the machine, the technician will know in advance what parts are required for repair, thus reducing service time.

Use of pressure sensors in the maintenance of pneumatic cylindersAs new sensor technologies emerge to monitor the performance of pneumatic actuators, the right maintenance strategy is essential for achieving optimal performance from the equipment. There are three kinds of maintenance strategies to evaluate: corrective maintenance, preventive maintenance and condition-based maintenance. Pressure sensing technology can enhance any one of the three maintenance strategy options.

Corrective MaintenanceCorrective maintenance is the practice of diagnosing and replacing components after they have failed.

Advantages:• Easy to implement• Minimal startup costs

Drawbacks:• Greater long term costs• Unexpected downtime• Multiple steps: one to diagnose the problem, a second to

repair the equipment• Difficulties managing repair part inventory

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Maintenance Strategies for Pneumatic Actuators( continued )

Preventive Maintenance Preventive maintenance is the practice of replacing a component on a set schedule.

Advantages:• Makes it easier to

budget repairs• Prolongs life of entire system• Supports product quality• Schedules maintenance

When to use:Preventive maintenance is not practical if the cost of maintaining the component is lower than the costs associated with its failure. When calculating the cost of component failure it is important to consider the effect one component has on the lives of other components in the system. Product quality can be influenced by component failures. Breakdowns in the middle of a production run could cause the loss of product, from a single unit to an entire batch.

Role of sensors:Preventive maintenance of pneumatic actuators is based on time in service or number of cycles. Because of the cyclical nature of preventive maintenance, that is, its occurrence on a set schedule, sensors play a limited role in this strategy. But new technologies allow pressure sensors to be installed near actuators where they can provide cycle count data. No longer is a magnetic rod and switch required to monitor cylinder position.

Drawbacks:• Could replace an

actuator that is still workable

• Failure can still occur without warning

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SIGN UP FOR AFREE INTELLISENSE® DEMO TODAY!Get 24/7 access to cylinder status details on 20 different performance variables with the IntelliSense® Software and the IntelliSense® Data Gateway.

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Maintenance Strategies for Pneumatic Actuators( continued )

Condition-Based Maintenance / Predictive MaintenanceCondition-based maintenance is the practice of monitoring the condition of components to determine when a component should be replaced prior to failure.

Predictive maintenance is an extension of condition-based maintenance: any changes in components’ conditions over time can be discovered and make possible a prediction about when the unit will break down.

Advantages:• Reduces downtime• Reduces inventory of repair parts• Avoids failure during critical builds• Maximizes life of actuator• Schedules maintenance • Improves product quality

When to use:Condition-based monitoring should be employed when the cost of monitoring the component is lower than the cost of component failure. This strategy leads to significant reductions in the cost of labor and the amount of downtime because technicians can replace components before they fail but not before they need to.

Role of sensors:Sensors are critical to the implementation of a condition-based monitoring strategy. Each actuator that is to be monitored will require installation of some instrumentation, either intermittently or permanently. The most effective approach is to permanently install a

Drawbacks:• Startup

costs• Increases

system complexity

sensor solution on the equipment. This simplifies data gathering and analysis. While intermittent monitoring can be effective, it is labor intensive and may miss signs of imminent failure. For pneumatic actuators, pressure sensors are ideal for monitoring the wear of piston and rod seals. Over time, increased air leakage or changes in actuator speed can be indicators of approaching failure.

ConclusionChoosing the right strategy for each application can be time consuming but with a little forethought there will be improvements in overall equipment efficacy (OEE). The increase in available sensors technologies has the potential to optimize any maintenance routine.

Jeremy King, CFPPS, is the IntelliSense® Product Marketing Manager with Bimba Manufacturing. Jeremy is an experienced product manager working with industrial sensors. Prior to working with sensors, Jeremy spent 11 years as a mechanical design engineer in the automotive industry.

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ORDERING INFORMATION

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For more information about Bimba’s IntelliSense®: Click, email or call:

708.534.8544

TOLL FREE:800.44.BIMBA