How digitisation helps SMEs save costs and energy

Lenze made itself an indispensable partner for machine builders in recent years by turning big data into smart data. The first steps towards greater energy efficiency and sustainability. At Hannover Messe 2023, it was time for the sequel. Lenze now wants to use that smart data and the resulting digital twins to reduce costs across the entire machine lifecycle by laying the foundations for open automation. Obviously with less energy consumption, but simpler engineering is also an added benefit. 

Big data, smart factories, Industrial Internet of Things...: data is currently the holy grail in industry. But although everyone is talking about big data, what companies really need most is smart data to increase productivity and reduce costs. Efficiency and innovation can be achieved even with less data. Lenze showed at the last Hannover Messe how it processes data intelligently. Don't think big, think smart, was the message from the automation specialist from Hamelin. Because the right data minimises losses of energy, time and material. There are two cornerstones to achieve this: the open automation platform Nupano, which makes it easy to integrate digital business models at machine level, and the digital twin as a collection point for all relevant information throughout the asset lifecycle.

Plans

Every machine naturally starts with a good design. Lenze's Easy System Designer enables optimal drive planning, including correct dimensioning and safe plotting of machine functionalities. Customers can use this web-based tool to virtually design their entire machine for the first time. What does that deliver? Machine modules that have already been tested and approved can thus be easily reused, reducing engineering time and effort. Moreover, improving energy efficiency and resource sustainability through more compact hardware is key.

Construction

The machine is now perfectly designed. Time to build it. That's where Lenze FAST comes in to help with its turnkey software engineering modules. FAST ensures that 80% of engineering can be done in 20% of time, thanks to its flexible and easily extendable framework for machine applications. A great example is Auto-Tuning. The automatic adjustment of the controller cascade in the servo inverter in 60 seconds means a noticeable reduction in workload and an improvement in performance. And speaking of servo controller, the new i750 portfolio Lenze presented at Hannover Messe combines efficiency, accuracy and dynamics in multi-axis systems, realising 10% faster cycles. A second notable hardware component on the stand was the c430 controller, which guarantees basic motion for compact machines.

Operate

Even during operation, machines must continue to excel in safety and efficiency to increase product quality and productivity. Many companies are therefore trying to move towards predictive maintenance. Lenze technology also points the way in that area. Via the Condition Monitoring and Asset Management modules, this becomes possible. Based on existing data, they look deep into the machine to evaluate performance and track machine availability within the production process. Data exchanged from the field all the way to the cloud, and poured into clear dashboards, also making OEE and Downtime Tracking perfectly possible. A new feature is the Drives Data Hub, the gateway between the data in the drive and these applications, so that they are fed with reliable data, without the need for additional components. The Drives Data Hub runs independently alongside the machine controller. 

Recycle

Finally, even when the machine is designed, thought must be given to how it can be recycled at the end of its life. This is in the hands of the digital twin, who can perfectly tell the processor what the machine consists of, where the material is installed and in what quantity. With this information in mind, work can be done on targeted recycling. The Product Passport contains all this data on the machine components and thus forms the basis for an efficient circular economy.■