Preventive maintenance is revolutionizing industry by detecting wear and tear on production machinery at an early stage thanks to advanced sensor technology and artificial intelligence. This enables effective planning of maintenance measures and minimizes unplanned downtime..
Preventive maintenance
These sensors measure mechanical wear in different ways:
This diverse sensor information is correlated and analyzed by powerful artificial intelligence software. With the help of statistical methods, precise forecasts can be made to determine the optimal time for preventive maintenance measures. This software is usually adaptive and becomes increasingly precise in its forecasts over time.
Preventive maintenance is an indispensable tool for ensuring production continuity and drastically reducing unplanned downtime. By integrating modern sensor technology and artificial intelligence into the maintenance process, companies are able to increase their efficiency and enhance their competitiveness.
At QuellTech, we use state-of-the-art 3D laser line sensors for preventive maintenance. These sensors enable the rapid detection of the height of tools or workpieces in seconds. But how does this impressive technology work?
Laser triangulation is an advanced technique for distance measurement and shape determination of objects based on the principles of geometry and optics. Here, the distance to an object is calculated using angles and known dimensions of a triangle consisting of a light source, a sensor and the object to be measured.
The error messages can be set from alarm to plant stop. The 3D point cloud can be saved as useful documentation for quality assurance.
By knowing the fixed distance between the laser source and the sensor, as well as the angle at which the laser light reaches the sensor, the points of the laser line can be calculated in height (z) and width (x). This results in a precise 2D profile. Multiple profiles taken at a specific distance from an object create a 3D point cloud. These calculations are performed in the 3D Laser Lines Triangulation Sensor using trigonometry and triangulation principles.
The accuracy of these measurements depends on several factors, including the precision of the angle measurement, the wavelength of the laser light, the quality of the optics, and the resolution of the sensor. Careful calibration processes are performed to ensure accurate measurements and account for potential errors or deviations in the system.
A concrete example shows how our technology is used in the preventive maintenance of production machines:
In a material crushing machine consisting of two large counter-rotating cylindrical rollers, the surface area and number of pins were recorded in a comprehensive 3D data file when new.
During the production process, the pins and the roll surface wear out. Every day, our QuellTech 3D laser scanner captures a complete 3D point cloud of the rolls and compares it with the data from the new condition. As soon as the measured height values of the pins and the roll surface fall below certain minimum values, an alarm is triggered. The QuellTech application software also makes it possible to create a long-term forecast and to specifically plan the timing of upcoming maintenance measures.
This approach makes it possible to plan the intervals between maintenance flexibly, yet precisely and with foresight, depending on the load on the rolls. As a result, we minimize downtime and maximize the efficiency of your production.
With our precise sensor technology, the actual wear of tools is measured directly and accurately. This enables an extension of machine service life, as maintenance measures are carried out exactly when they are really necessary.
With our precise sensor technology, the actual wear of tools is measured directly and accurately. This enables an extension of machine service life, as maintenance measures are carried out exactly when they are really necessary.
QuellTech’s preventive maintenance significantly minimizes the risk of unplanned machine downtime. Early detection of wear enables planned maintenance, avoiding costly interruptions.
Continuous monitoring and precise analysis of machine condition significantly increase productivity. Your production equipment runs more smoothly and efficiently, resulting in higher throughput rates.
The recorded data flows into a long-term forecast that makes it possible to track the course of wear over long periods of time. This allows you to flexibly adjust the machine service life to the actual degree of wear, while at the same time maintenance measures can be planned in good time.
Preventive maintenance with QuellTech reduces maintenance costs in the long term. By optimizing maintenance cycles and avoiding expensive emergency operations, your cost structures become more efficient and easier to plan.
3D laser sensor solutions from QuellTech offer an intelligent solution for preventive maintenance to extend the life of your machines, increase productivity and reduce costs. Rely on our technology to optimize your manufacturing processes and achieve competitive advantages.
Surface defects of a bearing raceway
Preventive maintenance is crucial in various industries. Here are some examples of application areas where this advanced technology is successfully used:
These examples illustrate how preventive maintenance with advanced sensors and data analytics is being used in various industries to increase efficiency, minimize downtime and improve overall production quality.
In the past, we have used Quelltech solutions for Preventive Maintenance in a wide variety of projects. Here you can find a small excerpt of these projects:
Q6-D
High resolution, large measuring width and high measuring rate (number of profiles) allow precise and large-area monitoring of the mold condition
Q5-D
Medium resolution, medium measuring width and very high measuring rate allow precise and fast monitoring of the mold condition
Q6 Laser Scanner
Q5 Laser Scanner
We are happy to help you with that!
Stefan Ringwald
Technical Consultant
If you have any questions about Preventive Maintenance or would like a consultation from QuellTech on this subject, we will be happy to help.
We would like to help you to precisely evaluate your specific measurement task. Through an initial free test measurement of your application, we can give you an early assessment of the feasibility.
There is always potential for improvement, we will help you with that. Contact us for more information or to make an appointment for a consultation.
By submitting the contact form, you agree that your data will be used to process your request (further information and instructions on withdrawal can be found in the privacy policy).
Your technically competent contact, Stefan Ringwald, will be happy to help you.
Our aim is to fully understand your specific technical requirements for your current measurement task.
Thanks to many years of experience with complex tasks in the field of 3D laser measurement, you will receive well-founded solution proposals from us.
