Learn about predictive maintenance solutions for the automotive industry, including SEW-EURODRIVE's DriveRadar software”

• Learn about what predictive maintenance is and how it’s managed
• Find out why predictive maintenance is important for the automotive industry
• Hear about SEW-EURODRIVE's predictive maintenance solutions, including DriveRadar

What is predictive maintenance?

Predictive maintenance is a system which works by analysing equipment data in real-time in order to predict potential issues before they lead to machinery or production line failure. It monitors ongoing performance to assess when equipment may need repairs, taking things such as vibration data and oil levels into account.

The move to predictive maintenance steps away from reactive maintenance (reacting to a breakdown as it happens) and preventative maintenance (the collection of data and assessment of machine performance after set time periods).

How does predictive maintenance software work?

Predictive maintenance software works by using sensors attached to equipment to capture and analyse performance data in real time, to predict potential issues before they lead to equipment failure or malfunction.

The five basic stages of predictive maintenance are:

• 1. Gathering of machine data through physical sensors, attached to machinery equipment like gearboxes
• 2. Transmission of the captured data from the sensors to a central system which can be accessed by engineers and operators
• 3. Analysis of data gathered, to predict potential upcoming failures or issues
• 4. Planning and scheduling of required maintenance to minimise downtime
• 5. Undertaking of action to repair equipment before a full breakdown occurs

Is predictive maintenance used within the engineering and manufacturing industries?

While implementing predictive maintenance can be hugely beneficial for those operating within the engineering and manufacturing industries, many are put off by the initial upfront cost of introducing the software across their facilities.

Machines can run for years without breakdowns, but when that breakdown eventually happens, the repair cost could be huge. Predictive maintenance works as an early warning system to plan downtime and repairs before issues spiral, having the biggest impact on industries where every minute lost can cost thousands.

While many production environments do have sensors installed to monitor various performance parameters, such as the temperature of gears, predictive maintenance software takes this one step further, constantly monitoring performance and flagging issues as and when they arise. This means a small problem can be dealt with easily and more cost-effectively than a larger surprise issue down the line.

What are the benefits of predictive maintenance for the automotive manufacturing industry?

In industries such as automotive manufacturing, downtime can be extremely costly.

The largely complex process of manufacturing vehicles, combined with the high production capacities of manufacturers, means that any equipment failure could end up costing millions per hour.

This means that those operating in the automotive sector have been some of the earliest adopters of predictive maintenance software, with leading UK car manufacturers, such as BMW, helping to reduce the risk of downtime, and therefore minimising operating costs.

One car manufacturer / BMW introduced SEW-EURODRIVE's predictive maintenance software within their production processes , DriveRadar®, and saw immediate results. Not long after adopting the software, they were able to predict a breakdown, that they then managed to repair for a fraction of what it would have cost had the machinery failed entirely.

The maintenance was able to be planned in over the Christmas downtime period, meaning the production line could continue as normal around the repair time, and there was no additional disruption as a result.

What is DriveRadar®?

Here at SEW-EURODRIVE, we’ve developed the comprehensive predictive maintenance software, DriveRadar®, which uses sensors installed within gear units to capture data such as vibration behaviour of rolling bearings, oil temperature, level, and viscosity, and input speed.

This data is collected, analysed, and interpreted, to forecast things such as potential gearing damage, the remaining service life for bearings and gearing, and when the next oil change is needed.

The data is then visualised in the DriveRadar® IoT Suite, where, at a glance, you can see the current status of the gear unit, and all its individual components.

When a limit value is exceeded, the system notifies you immediately and provides you with direct recommendations for solving issues with the gear unit.

You can also access all the information you need within the DriveRadar® IoT app, providing you with mobile assistance wherever you are. SEW-EURODRIVE engineers are always on hand too, to provide you with further advice on any issues, or aid with potential repairs.

If you’d like to learn more about implementing predictive maintenance software in the automotive industry, speak to our team info@sew-eurodrive.co.uk