GUNT-DigiSkills 3

Preventive maintenance

GUNT-DigiSkills

 

The teaching of digital skills in training students and professionals takes an essential part due to the increasing digitalization of work processes in the context of Industry 4.0.

GUNT-DigiSkills learning projects can help you to meet the new requirements of education: digital skills are covered from basic to more advanced.

Nowadays, production plants have a 24/7 availability. Predictive maintenance enables this continious operation.

Condition monitoring of critical components is part of the concept of predictive maintenance. The time of maintenance or replacement is thus defined. This learning project is based on » MT 174 Sorting plant including real operation processes.

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GUNT-DigiSkills 3

Preventive
maintenance

  Logo Titel  
Logo L1 Logo L2 Logo L3 Logo L4 Logo L5

GUNT-DigiSkills

 

The teaching of digital skills in training students and professionals takes an essential part due to the increasing digitalization of work processes in the context of Industry 4.0. GUNT-DigiSkills learning projects can help you to meet the new requirements of education: digital skills are covered from basic to more advanced.

 

Nowadays, production plants have a 24/7 availability. Predictive maintenance enables this continious operation.

Condition monitoring of critical components is part of the concept of predictive maintenance. The time of maintenance or replacement is thus defined. This learning project is based on » MT 174 Sorting plant including real operation processes.

Poster Prozess bersicht

 


Didactic concept

 

MT174 mit Getrieben

The sorting plant includes three gearboxes, which accompany us through all process steps of the entire learning project. The entire, closed process for replacing a gearbox covers 10 process steps, from the maintenance message to the completion message. The process is IT-supported, using a wide variety of digital elements and technologies.

 

Overall preventive maintenance process

 

Gesamtprozess waagerecht
Gesamtprozess waagerecht


Maintenance message
Condition monitoring & predictive maintenance

 

In more complex plants, systematic machinery condition monitoring within predictive maintenance is a well-established process. Extensive software applications are available to manage machinery condition monitoring. The remote transfer of data and the generation of maintenance work orders are also part of the process.


The maintenance message is initiated:

  • time-controlled, in case the maintenance interval has passed
  • sensor-controlled, in case a limiting value is exceeded
Screenshots MT174 Instandhaltung

Time-controlled maintenance

An operating time counter in the PLC of the » MT 174 Sorting plant allows time-controlled maintenance of the three drive trains:

 

  • rotary storage table drive
  • conveyor belt drive with dosing hopper
  • drum screen drive

 

Once a maintenance interval is passed, the plant stops and a message is displayed in the PLC.

Getriebe mit Heizer

Sensor-controlled maintenance

For monitoring the rotary storage table drive, the menu additionally offers a sensor-controlled version of the monitoring. For this purpose, the gearbox is equipped with an electric heater and a temperature sensor. The oil sump of the gearbox can be heated electrically causing the lubricating oil temperature to rise and reach a limiting value.

 


 

PT501

Add-on experiments

Various types of damage to roller bearings can be precisely diagnosed by vibration analysis. The experimental unit » PT 501 Roller bearing faults enables fast and very clear experiments with the help of a powerful software.

 

 


Work order to service team
Replacement of gearbox no. XY/3 on unit no. XY

 

Auftrag Serviceteam
The plant management issues a work order to the service team for the replacement of the gearbox. The work order lists the exact name and position of the gearbox at the plant. In industrial production plants, the work order issuance can be automated. The work order is then transferred automatically from the plant control system to the service team by e-mail, for example. Sprechblase

 

 


Replacement of the gearbox

 

In case of a necessary maintenance work, the primary priority is to reduce the plant downtime to the absolute minimum. For this reason, the service team stocks a ready-to-install, tested replacement kit: spur and worm gear with drive motor.

Media Center

Before the service technician (here student/trainee) begins any work on the operational plant, preparations must be carried out based on technical documents. The technical documents, such as assembly drawing, parts list, assembly/disassembly instructions, tool and jig list can be accessed via QR code in the GUNT Media Center.

 

» Login GUNT-Media Center

  

To perform the service process, the DigiSkills learning project offers two options:

  • virtual option, visualized by augmented reality
  • real option, hands-on realization
Augmented Reality mit Tablet

Virtual by augmented reality

The augmented reality environment visualizes all the assembly steps. The following actions are required for access:

 

  • installation of the free Vuforia View app
Vuforia View » Google Play Store
» Apple App Store
  • configuration of the app
  • using the app
Ausbau Getriebe

Real, hands-on

The entire drive train can be removed from the MT 174 Sorting plant. It is disassembled such that the motor and gearbox remain as individual units.

In case the gearbox should be disassembled into its individual components, it is necessary to switch to the corresponding assembly exercise MT 123 Spur and worm gear from here on.

 


Message about successful replacement of the gearbox

 

Meldung Austausch
Sprechblase After the gearbox has been successfully replaced, the service team immediately contacts the plant management so that the plant downtime can be terminated.

 

 


Work order
Overhaul of the removed gearbox

 

Auftrag Serviceteam
The spur and worm gear removed from the sorting plant is overhauled in general. After testing with proof of full functionality, the component is stored and ready for the next circuit of the maintenance process. Sprechblase

 

 


Scheduled disassembly of the gearbox and definition of spare parts required

 

During scheduled disassembly, the gearbox is disassembled and subjected to cleaning and inspection.

MT123 mit Auszubildenden

For the disassembly and assembly we use our assembly exercise » MT 123 Spur and worm gear. The kit offers a gearbox constructed in the same way as the one installed in the MT 174 sorting plant. In difference, however, the kit included in the assembly exercise is specially prepared for easy assembly/disassembly, suitable for classroom desks.

Media Center
Next generation assembly exercises - Education 4.0

GUNT assembly exercises combine classic learning content with digital content and methods. They include hardware on an industrial level and a digital data package.

 

The GUNT Media Center serves as the platform providing digital data for tablet, PC or smartphone via the internet. Customers can access files and product information of selected products independent of time and place. The data includes CAD files as STP or DXF files as well as PDF files and videos.

 

» further information 

 

GUNT-Media Center contents

 

MC 3D

3D drawings

MC Video

Videos

MC Explosion

Exploded views

MC Tech Zeichnung

Engineering drawings and lists of parts

MC Anleitung

Manuals

MC Übungen

Prepared exercises

 


Spare parts acquisition

 

We realize that a certain component from our gearbox has to be manufactured because it is not available from stock and external acquisition would take too long. Due to time constraints, we decide to use additive manufacturing.

Ersatzteilfertigung

The students access the GUNT Media Center via QR code and check the available data for this gearbox. They identify the required part with the help of the included parts lists and single-part drawings. For 3D manufacturing, the STP file included in the GUNT-Media Center is the basic document. A common 3D printer, e.g. GUNT laboratory 3D printer, can be used for this purpose.

3D Druck

The students are concerned with the work order for 3D printing, learn which data must be provided and get a general overview of additive manufacturing itself. The students acquire information about the materials used in 3D printing, manufacturing tolerances, strength and limit stresses, additional work required, etc.

 

 


Scheduled reassembly of the gearbox

 

MT123 mit Auszubildenden

The disassembled, inspected and cleaned » MT 123 spur and worm gear is assembled again.


Besides the video on disassembly, the GUNT Media Center offers a video on assembly. It shows the assembly step by step, including the tools and jigs.

Media Center
Next generation assembly exercises - Education 4.0

GUNT assembly exercises combine classic learning content with digital content and methods. They include hardware on an industrial level and a digital data package.

 

The GUNT Media Center serves as the platform providing digital data for tablet, PC or smartphone via the internet. Customers can access files and product information of selected products independent of time and place. The data includes CAD files as STP or DXF files as well as PDF files and videos.

 

» further information 

 

 


Functional test for quality assurance

 

After successful reassembly, the gearbox is subjected to a functional test under real conditions:

  • over a defined period of time
  • under defined loads
MT173

In order to complete the overall process in class practically as well, we use » MT 173 Test stand for gears.

 

The reconstituted gearbox is inserted into the test stand, including positioning and fixing of protective covers. A PLC with touch screen is used for control and offers many supporting menus for test execution, display of test results and graphical support for the mechanical setup.

 

 

MT173 Screenshot Prüfergebnis

Test results

The test run is automatically controlled by the PLC. Switching to manual operation is also possible. Screenshots can be saved, integrated into a test report, converted into other formats or sent as a file. Graphical visualizations can be modified in many ways.

MT173 QR Scan

Via the QR code you can access the GUNT Media Center for extensive information and teaching material, provided on purchase of the test stand MT 173.

 

  


Completion message after finishing the entire process

 

Lager
Sprechblase The gearbox is now completely overhauled and the plant management is informed.
After testing with proof of full functionality, the component is stored and ready for the next circuit of the maintenance process.

 

 

 


 

Overview of devices involved in the overall process

PT501 0

Additive manufacturing

Laboratory 3D printer, order number: 609.00000A00185

Add-on experiment: machinery diagnosis

» PT 501 Roller bearing faults


 

Digital learning objectives at a glance

 

Augmented Reality

The following elements for the development of digital skills can be realized with the overall system GUNT‑DigiSkills 3:

 

  • maintenance routines at a production plant, digitally monitored and visualized with a Siemens PLC
  • use augmented reality (AR) for the scheduled maintenance steps at the sorting plant
  • understand the concept of preventive maintenance and learn the basics of machinery condition monitoring
  • understand and be able to describe the terms condition monitoring & predictive maintenance
  • information availability via a portal: data from the GUNT Media Center with access via QR code

  • get to know and use file formats practice-oriented: PDF, DXF, STP, STL, etc.
Lehrsituation MT 174
  • information search and visualization of processes with different end devices, such as PC, notebook, tablet, smartphone
  • understand a digital, closed loop process flow: ERP system or other database-driven information concepts
  • learn about additive manufacturing, understand and execute the required data transfer
  • get to know an automated test of gears as a quality assurance element
  • use standard software throughout, become familiar with screen mirroring; let digital communication become standard

  • understand and be able to describe basic concepts/characteristics of Industry 4.0

 

 


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Tender specifications

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