Iveco is a global manufacturer, among others. of trucks and commercial vehicles. At the Suzarra plant near Mantova in northern Italy, 250 “Daily” vans roll off the production line every day. In Iveco's so-called body shop Body composed of trucks and commercial vehicles. sweatrobot join pre-punched sheet metal parts on a 100 m long production line. The diagnostic tool LR Smart Observer and different sensors from IFM Electronic provides condition-based maintenance there.

Contents

• Beginning wear and failure analysis
• Alarming vibration diagnosis
• Reliable fluid monitoring
• Digital IO-Link data transmission

Beginning wear and failure analysis

The Iveco bodyshop represents a critical point, because a standstill at this point would stop the entire production. That is why Iveco, together with the automation specialist, has a comprehensive range Diagnostic system installed for condition monitoring, which allows condition monitoring and thus effectively prevents unplanned production downtimes. 

Condition monitoring started with Analysiswhich mechanical parts in the machines are particularly critical with regard to wear and failure are. Whether assembly lines or lifting platforms: the greatest mechanical stresses arise on them, more precisely on their bearings. A damage event at this point of the machine would result in a substantial production stop.

Amodio Cioffi, Maintenance Engineering Robot Iveco SPA: “We decided to carry out condition-based maintenance on the most important line in the body shop, as all variants of the van are produced there. In this production line, the side parts are first guided to the floor assembly. The crossbars are then attached and then the roof is put on. Transport to the welding stations is fully automatic. The various body shell variants then go into further processing.”

In order to ensure maximum availability of the system, impending wear and tear on machine components must be detected at an early stage. Fabio Piccinelli, WCM Plant Support Iveco SPA: “For continuous improvement, we are always looking for new technologies to increase efficiency and productivity. When it comes to maintenance, we have moved from cycle-based maintenance to condition-based maintenance with significant cost savings.”

Alarming vibration diagnosis

Specifically, this meant that all the mechanical parts of the plant were being used vibration sensors installed by IFM. The cylindrical sensors of the type VSA are screwed directly to the housing of the respective bearing or gear. The separately installed evaluation units VSE continuously analyze the vibration behavior.

They detect imminent damage caused by imbalance and give the alarm in good time. Guiseppe Sotira, Body Shop Technical Engineering Iveco SPA: “All the sensors installed help the maintenance staff to State of wear to recognize every component in real time and to take any necessary maintenance measures before real damage occurs. ”

Reliable fluid monitoring

Condition-based maintenance goes far beyond monitoring mechanical components. An example is that Monitoring the coolant in the welding guns. Clogged filters or leaks are possible sources of error. Monitor here Flow Sensors for small flow rates of type SBY the flow and pressure sensors of type PN the pressure in the lines.

The central cooling circuit system, the flow sensor SM monitors the flow. The compressed air system is reliably monitored with an SD. Even the smallest leaks are reliably detected.

Digital IO-Link data transmission

All sensors transmit their measured values ​​digitally via IO-Link. Roberto Militello, Body Shop Maintenance Iveco SPA: “IO-Link transmits the data digitally for reliable process control. The measurement signal is converted into digital data in the sensor and forwarded.

Furthermore, we can switching points of the sensor for pre-alarm and alarm can be programmed directly from the server without having to go to the sensor on site. We can see and calibrate the sensor in the server. When replaced, programming is no longer necessary.”

As a Software the "LR Agent" is used. It collects the data from the sensors and stores them in a Microsoft SQL database. The software analyzes and displays this data LR Smart Observer. Guiseppe Sotira again: “The LR Smartobserver software monitors and manages the measurement data from all sensors.

The display options for the parameters show a transparent image of the entire production system. Every event can be read exactly. The system sends messages such as pre-alarms or alarms by email.” The Smartobserver enables condition-based maintenance, which fits perfectly into the Industry 4.0 concept.

3D Camera | Industrial image processing

IFM installed the system for Iveco during operation without having to stop production. In parallel operation, the new system could be tested extensively and it has proven itself. Imminent damage is now recognized early and rectified without production downtime. In conclusion, Guiseppe Sotira sums it up: "Thanks to this cooperation with IFM, Iveco is ideally equipped for Industry 4.0".

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