- No errors during guided format change
- Ultra-flat sensors for wafer production
- Intelligence included
- Faster cartoner changeovers with Balluff’s Guided Changeover Solution results in 50% less downtime
- Enhancing maintenance strategy with Balluff's Condition Monitoring Toolkit (CMTK)
- Never run out of compressed air
- Precision gearbox assembly machine for residential water meters
- Continuous production monitoring in folding machines
- Reliable container test with artificial intelligence
- Flexibly expandable and modular image processing system
- Image processing in hospitals
- Not just “click clack”
- Easy guided format change
- Condition Monitoring for a clear view
- Reliable Tap Water Supply – Setting a Sustainable Standard
- Flexible feeding systems using reliable sensors
- Reliable clamping processes and reduced downtime with ultrasonic sensors
- An AI-powered pharma line clearance solution
- Efficient cleaning of food tanks
- Industrial cameras in steel processing
- UK Battery Industrialisation Centre
- Training Tomorrow’s Engineers with Balluff IO-Link and Condition Monitoring
Never run out of compressed air
DRIVR powered optimization with the Balluff CMTK
Branche: Plastic and rubber industry | Customer: Centroplast GmbH, Germany
Over the years, Centroplast have continuously expanded their expertise and is proud to extrude thermoplastics and manufacture high-quality components and assemblies.
As a renowned plastics specialist, they not only focus on high-quality semi-finished products, but also offer customized finished parts in small or large series. Their focus is on developing sophisticated technical solutions that meet customer specific challenges and applications. And that is the point that Centroplast and Balluff have in common. The neverending search for the best solution for the customer.
Situation
Centroplast was looking for a safe and easy solution to secure the constant work of the air compressor. That solution was urgently needed because in case of a compressor breakdown, the production needs to stop. And these unplanned downtimes are the worst case scenarion in every production line. The aim was to use sensors to enable predictive maintenance for an ageing compressor at Centroplast and thus avoid costly replacement purchases.
Challenge
Many production facilities have systems and machines that are critical to the processes but do not have digital interfaces for monitoring and control. In this case it was a compressor at Centroplast that was critical to the production process. The purchase of a completely new machine or the development of a special sensor-based control solution was quickly ruled out for cost reasons.
Solution
To support retrofitting the machine, the Condition Monitoring Toolkit (CMTK) from Balluff - supplemented by special pressure sensors for monitoring the storage tank – is used. Together with the connection to the IIoT platform DRIVR and Google Looker, signs of wear could be detected at an early stage and appropriate measures taken. So no connection or changes to a classical PLC were needed here.
Steps of Implementation
The implementation of the CMTK and the associated sensors was comparatively simple and was completed within a few minutes. The data was recorded using the IO-Link evaluation unit supplied and forwarded to Google Looker using the IIoT platform DRIVR. The installation of the sensors, the setup of the IIoT platform and the creation of the dashboards were completed within few hours, meaning that the system can now be monitored efficiently.
Why is this the perfect solution?
The decision in favor of the Balluff CMTK was based on its comprehensive range of high-quality sensors, industry standards, such as IO-Link, and simple data evaluation.
The use of other sensors would have required more effort when setting up the gateway. DRIVR was chosen for the IIoT solution because it offers transparent cost structures, is directly usable without additional coding, easily scalable for adding future sensor data, and focuses on important, basic functions.
The integration of Google Looker enabled an intuitive and visual representation of the data, providing an immediate overview.
This system was easy to integrate and offers us great and valuable insight about our compressor. Now we feel much better and safer and we can focus on our main business. Balluff provided perfect support and we are happy about the solution.
Benefits
- Combining new and cutting-edge solutions to analog equipment offers many advantages
- Know whats happening without buying a new machine
- Do your retrofitting cost efficient and effective
- Make the most out of the data by interpreting it the right way
- Save hours of unplanned downtime due to unexpected breakdowns
- Save your time, money and nerves
Products
The monitoring of systems without digital interfaces can be realized efficiently and cost-effectively with the help of sensor technology and the right IIoT platform. The application example at Centroplast illustrates how the use of Balluff's CMTK, the IIoT platform DRIVR and Google Looker enabled seamless monitoring and optimized maintenance.