Remote service solutions for remote maintenance and service purposes have prevailed across the board. With the concept of a digital twin comes for Harting Now the next logical step: The virtual representation of systems installed around the world makes service calls easier and creates new possibilities for, for example Condition monitoring.

Harting digital twin

 

Content of the technical article


The numerous Hidden champions of the German mechanical engineering sector believe they are in a false sense of security in view of the good situation, according to a study by Roland Berger. Customers like that Automotive industry need less capacities, technological change with digitization and additive manufacturing requires considerable adjustments and finally new competitors, especially from China, are taking over additional market shares.


Iguverse Igusmetaverse | My first experience with the Iguversum


With additional offers in service and after-sales, machine-builders could better differentiate themselves from the competition and thus increase sales and margins. This requires a good database and appropriate resources. The study concludes, however, that this service potential is still often wasted. This is where the concept of the digital twin comes in.

Great potential for digital services

Harting Hanover Fair


The Service For machines and systems installed around the world, the warranty phase is a highly relevant cost factor for machine manufacturers. Every on-site deployment of a technician that can be saved through online access is worth real money. The subsequent operating phase is already being used by many providers for additional online service offers. With the further development of the available technologies, machine builders can open up numerous new possibilities.


Unitechnik digital twinDigital twin allows retrofitting during operation


Today, a virtual model of machines and systems can be created with significantly less effort. In the future, such digital twins will accompany the entire life cycle, from development through planning, commissioning, operation and optimization of processes to after-sales. Clear visualizations and new assistance systems simplify access to machines installed worldwide and the Communication the experts with the machine installed at the customer.

“Far too few companies still use such virtual prototypes of machines, systems and production lines to simulate the design, functionality and efficiency in advance and thus save time and money. According to the prognosis, the picture will change by 2020: Then various digital aids for simulation will be in use by more than 90 percent of mechanical engineers and have a positive effect on the entire value chain ”, analyzes the global study" Industrial Goods Study 2018 "by Alix Partners.

Digital twin for the entire product life cycle

Harting digital twins


Digital twins as virtual digital images are also for the beyond the development phase condition monitoring and service planning of machines and systems in operation is extremely helpful. Operating, status and process data are recorded by or through sensors Machine controls provided. Product developers, production planners or maintenance staff use the information from the real counterparts for planning, monitoring and control. Above all, this opens up new business prospects for machine manufacturers.


Unitechnik intralogisticsDigital twin supports planning in intralogistics


Experts, for example, do not have to be flown in at great expense, but can support the local service technician on site online. This reduces the costs of maintenance work and does not tie up skilled workers with endless travel times. New business models are only possible through digital twins. Why not sell production output instead of machines?

Aircraft turbine manufacturers are already successfully offering this model to airlines. At the same time, the data from permanent condition monitoring can be used to document the warranty and for continuous product improvement.

Edge Computing and Meeting Point Architecture

harting50219Harting has worked with partners such as the company Perfact innovation from Herford in East Westphalia Edge Computing Solution developed for digital twins. Very different problem-solving skills are brought together here:

The connection of machines with the most diverse interfaces on the “last mile”, the definition of data structures, basic analysis functions, the visualization of selected machine parameters and safe access to the machine from outside.

In practice, the biggest challenge in the highly heterogeneous machine park. They have grown over many years and often only have proprietary interfaces and automation protocols. For these requirements Perfact uses the open and modular concept Mica Mini computer. Depending on the machine and application, suitable interfaces, selected sensors and the appropriate software are combined into a finished solution package. This means that both new systems and legacy systems can be recorded.

Four eyes principle over internet connection

The Mica enables access to the machine and records the machine data. The Perfact Meeting Point Architecture (MPA) organizes the safe maintenance work with a service management. The meeting point server serves as a node and database. It links the machine control computer, customers and workplaces of the remote maintenance staff via secure internet connections. That applies here Four-eyes principle. In this way, the technician at the customer's site can safely access the same data with a specialist connected via the Internet.


Mitsubishi digital twinDigital twin processes data in the cloud


The database makes both current data and a consistent system history available centrally. In addition, selected system data are displayed in a dashboard Real time visualized. The components of the solution also include an integrated service workflow with its own ticket system. Maintenance management with maintenance instructions and maintenance planning can thus be set up for condition-based and proactive maintenance. Options include, for example, a mobile maintenance workflow and access via mobile service apps.

The most important advantages include accelerated planning and commissioning cycles, the availability of current system data from locations around the world, and improved remote service solutions. The remote service can be used as the first stage for further service offers. By expanding the analytics capabilities, approaches such as condition monitoring and in a further step Predictive Maintenance implement. In this way, machine / system availability can be increased, maintenance / service costs can be reduced and customer loyalty can be improved through improved service.

Smart factory with digital twin

Harting has its own smart factory Haii4you (Harting Integrated Industry 4 You) implemented a comprehensive Industry 4.0 solution. A completely vertical integration from the user to flexible product manufacture is demonstrated. A digital twin of the system is created together with Perfact Innovation. Dr. Jan Regtmeier, Director Product Management at Harting IT Software Development presents the digital twin.

You might also be interested in...

industrial housing | Indoor and outdoor control boxes

industrial housing | Indoor and outdoor control boxes

Industrial housings have to withstand tough environmental conditions both indoors and outdoors. To do this, manufacturers...
Electrical Wires | From cable to assembly

Electrical Wires | From cable to assembly

Cables and wires are the lifelines of modern technologies in industry. From power transmission to...
RFID and Barcodes | Industrial identification

RFID and Barcodes | Industrial identification

Efficient and transparent processes are essential in modern production. Possibilities for optimization offer here...
Ethernet switches | The data driver in the network

Ethernet switches | The data driver in the network

In a world that increasingly relies on connectivity, reliable and efficient...
Reduce carbon footprint | That's how it's done!

Reduce carbon footprint | That's how it's done!

More and more companies want to reduce their CO2 footprint in order to combat climate change with various...
Charging plug, charging cable | For the electric car

Charging plug, charging cable | For the electric car

Which e-car owner does not always want an efficient, fast, reliable and available charging option...

Author information
Thomas Holthöfer

Thomas Holthöfer, Regional Digital Marketing Manager, Harting Germany.