Surface World February 2019 SW_Feb_2019_LR | Page 70

PAINT & POWDER
IIoT solution monitors paint booth online
EcoScreen Equipment Analytics optimises
plant availability and product quality
Dürr EcoScreen
Equipment Analytics
brings transparency and
intelligence to paint shops
processes. The newly
developed solution for the
Industrial Internet of Things
(IIoT) evaluates all robot
and process data, traceable
down to the millisecond, so
that faults can be quickly
identifi ed and rectifi ed.
The technological highlight
is a streaming analytics
application for real-time
data analysis.
What is happening in the painting cell and
what is the condition of the technology?
EcoScreen Equipment Analytics provides the
answers. The software records and analyses
all relevant signals from the sensors and
actuators integrated in Dürr painting robots.
The application technology of the front robot
arm, for example, permanently provides data
on the pressure regulators, metering pumps
and colour valves. Main needles, turbine
speed, shaping air and air heaters from
the electrostatic rotary atomizers are also
connected to the data recorder. The software
also records the positions, torques, and
temperatures of the painting and handling
robots’ individual axes. Data from the
conveyor technology is additionally collected
for the positions of the bodies in the painting
booth. This information is compared with
data from the painting cells, such as start
and end time of painting, or production
data for individual bodies such as type and
color code. All errors and warnings from
the painting process are also collected.
Visual representation
creates transparency
In addition to data recorder and database,
the IIoT solution comprises a visualisation for
the graphical representation and analysis of
the results. “With the help of the Visual
Analytics module we can precisely trace the
data from the previous weeks with
millisecond accuracy,” explains Dr. Lars
Friedrich, President and CEO of Dürr Systems
AG. “The detailed information helps us to
identify and eliminate faults quickly. The cross
comparisons of different robots improve root
cause analyses and help the plant operator
to boost plant availability, increase the
EcoScreen Equipment
Analytics is the latest
product from Dürr’s Digital
Factory. The software
continuously collects and
analyzes data from the
paint shop, making
painting processes
transparent and effi cient.
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first-run rate, and improve the overall process
sequence.” This creates transparency. For
example, the signals collected from the
metering pump together with flow rates,
pressure regulators, and main needles of the
atomisers can be displayed synchronously
on the control computer and correlations can
be defined. The software can display these
process signals in a 3D view together with
the trajectories traveled by the robots and
the exact position of the body, and perform
a comparison. By superimposing the signal
curves, EcoScreen Equipment Analytics can
also compare bodies by type and colour.
Algorithms calculate the
ideal plant condition and
show anomalies
The additional module Streaming Analytics
goes one step further: it analyses the data in
real time. Using algorithms, it calculates
patterns and correlations that describe the
ideal plant condition from the data collected.
Even the smallest anomalies both within the
plant and in the process are automatically
identified. Employees can initiate
corresponding service measures straight
away and get to the bottom of the deviation
before the body even leaves the paint booth.
EcoScreen Equipment Analytics uses software
from the IIoT platform ADAMOS for the
streaming analytics function. Dürr operates
ADAMOS together with Software AG
and several mechanical engineering
companies.
Model-based
plant monitoring
Streaming Analytics provides the plant
operator with easy-to-use graphical
interfaces that do not require any
programming expertise to create analysis
models. For this, Dürr developed a Model
Editor that provides the user with a library
of analysis modules. These can also be
individually combined into new models
(e.g. a model for monitoring the painting
pressure during application). The data
is displayed graphically on the screen.
The operator can see that all values are
FEBRUARY 2019
read online: www.surfaceworld.com