19.11.2015

Detecting faults before they become a problem - that is the aim of this new FeinMonitoring service. To achieve this, Feintool has developed a new type of intelligent online system to monitor fineblanking presses and to predict faults. Sensor data taken directly from the machines reveals when and how intervention is required.

The most reliable machines of all are cars. They're on the road for decades and cover hundreds of thousands of kilometres. One reason for breakdowns becoming less and less frequent is timely visits to the workshop whenever certain figures exceed a particular threshold. Newer models are simply packed full of sensors and warning lights which immediately let the driver know about everything from tyre pressures to the lights if anything goes wrong. The flood of data continues right into the workshop where, to help them diagnose and repair the fault, manufacturers will have already collected and stored information about every possible problem.

Feintool is now applying this tried and tested system to its fineblanking presses. Under the title 'FeinMonitoring ', it has developed a new type of intelligent online system, specifically for monitoring fineblanking presses. The special feature of the system is that it operates totally independently - without any user intervention. At the customer's request, Feintool will now retrofit HFA plus and XFT presses, equipping the systems with sensors that record values such as oil temperature, moisture content and purity. Electricity consumption, cutting impact, motor temperatures and control system temperatures will also be measured. Together with the other data recorded via the control unit, these figures are used to produce a comprehensive picture of the system's status.

In an emergency, Feintool's experts can use data from sensors to quickly identify problems.

A new maintenance concept model
As a result, FeinMonitoring helps customers to reduce unscheduled downtimes and outages to a minimum. The system uses well-proven analysis procedures to extract meaningful information from the data recorded. Thanks to the monitoring of a wide range of parameters, changes in the overall behaviour of the press are promptly detected; for example, by monitoring characteristic patterns in the relevant signals and sensor data, which are transmitted via a secure wireless connection to the Feintool Smart Maintenance Database. Software running in the background then evaluates the data using special algorithms. In the event of a warning message, Feintool analyses the data and if necessary notifies the user about any action to be taken, such as an impending oil change, preventive maintenance or a repair. And all done with the primary aim of detecting and correcting faults promptly, before they become a problem. Feintool technicians will also carry out this work either on a one-off request basis or as part of a general maintenance agreement.

A maintenance milestone
Maintenance manuals for each press, containing recommendations about the frequency with which parts subject to wear and consumables should be replaced, used to be the standard practice. That minimized the risk of serious damage and faults. But maintenance manual recommendations are inflexible and are oriented to the number of operating hours. They do not take into account the way the press is operated, for example the stroke rate and pressing force used nor the stresses to which individual components are subject. Thanks to FeinMonitoring, components are no longer replaced too early, but only when a failure seems imminent. This exploits the machine's service life to the full and achieves cost savings. FeinMonitoring gives customers genuine planning security with these functions. Expensive outages are avoided because targeted checks and preventive measures ensure that the systems have optimum availability, and capacity is used to full effect.

Another advantage of using FeinMonitoring in support of press maintenance is that Feintool, as the manufacturer, can compare the fault data of all machines of the same type, recognize patterns and hence continuously expand its knowledge about the system's wear behaviour. Data solely related to the machine's technical performance is analysed by experienced servicing staff and by Feintool's development engineers and the action to be taken is worked out in conjunction with the customer's maintenance team. Experienced fineblanking press experts are yet another benefit which Feintool is able to offer.

Download the FeinMonitoring graphic here

Brief Profile of Feintool

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