Digital Twin

Explore intuitive vibration diagnosis

Digital Twin

Explore intuitive vibration diagnosis

Intro

It’s all about Data-Driven Decision Making

The industry faces challenges in optimizing production processes and achieving climate-neutrality while managing costs. Digital Twin technologies offer solutions to these challenges. The Digital Twin is a tool for enhancing availability and productivity, reducing maintenance and energy/environmental costs, and enabling informed decision-making based on operational data.

But what is the Digital Twin? For us, it’s a unique digital representation mirroring the physical object. Integrating all relevant data into a dynamic multi-domain model, it evolves throughout the plant lifecycle to remain an up-to-date counterpart. The combination of operational experience and our expertise in process engineering, instrumentation and control creates a synergy that unlocks amazing opportunities!

Representation of the process of data transfer from a machine to the digital twin - Darstellung des Prozess der Datenübertragung einer Maschine in den digitalen Zwilling

Services

Following Plant’s Lifecycle

The Digital Twin supports decision-making throughout the entire plant lifecycle, from planning to modernization. It generates a highly accurate, dynamic process model using provided design and process data. Our simulation environment, equipped with powerful optimization algorithms, drives the evolution of the Digital Twin throughout its lifecycle. By merging design and field data, it provides a holistic view of the plant, offering valuable insights into its operation.

Pictogram data

Simulation-aided Engineering

The Digital Twin helps in selecting control strategy and actuators. This ensures best dynamics and optimal control performance for the machine and for the overall process.

Pictogram touchpoint

Virtual Commissioning

Run the Digital Twin against plant control for ultra-realistic testing of closed-loop control, sequences and hazardous situations. Save time and cost during hot commissioning.

Pictogram Present

Operator Training

Use the Digital Twin to train normal and abnormal  operation as well as hazardous situations without affecting the plant. Reduce the risk of improper operator reactions.

Pictogram Search Data

Virtual Troubleshooting

The Digital Twin identifies the root cause of process interruption or breakdown and offers a tailored solution. Avoid unplanned downtimes and restarting delays.

Smart Monitoring

With the Digital Twin, monitoring becomes a continuous benchmarking process. Comparison with the reference operation shows how well the machine or plant is currently working.

Pictogram wrench - Piktogramm Schraubenschlüssel

Smart Maintenance

Beyond Smart Monitoring, the Digital Twin detects abnormal plant behavior and assists root cause analysis. The plant health can even be extrapolated to predict future degradation.

Pictogram circuit

Smart Revamp

The Digital Twin discovers potential for improvement and increases the efficiency of machine operation and the process itself. Powerful optimization algorithms consider technical, financial and environmental factors.

Use Cases

Explore amazing Opportunities

Loading...

Whether you need a standard rack, a customized terminal box, a mobile measurement device or even a tailor-made distributed CMS with special algorithms. Combine a quick and effortless rollout in the field with a CMS solution tailored to your exact needs.

We help you build a standardized data backbone for applications such as predictive maintenance. Our open and easily extensible system architecture allows integrating new M2M interfaces or export to specific data formats. You can also rely on our expertise in developing your analysis tools.

Our vibration analysis services for rotating machinery such as compressors, turbines, expanders and pumps can help you optimize your plant reliability. We provide support as part of regular operational data analysis as well as diagnosis of emerging or existing machine problems.

No system covers all applications. So, different CMS have proven themselves for different applications. That is why we also integrate third-party systems and help merge data.

We do calibration for proximitors and accelerometers. Beyond that we support you in identifying problems in the measurement chain to restore trouble-free operation.

Integration

?????

Hardware Integration

Software Integration

The CCM C-421 edge module is compatible with a wide range of industrial sensors, including proximity, velocity, acceleration, keyphasor, speed, and pressure. The system features a configurable power supply, supporting -24VDC, +24VDC and the IEPE/ICP standard.

Rack-based machine monitoring systems like Bently Nevada 3500 and Brüel & Kjaer VC 6000 etc. offer Buffered Out connectors for enhanced functionality. Integrating our CCM system with these connectors allows seamless retrieval of raw sensor data. This integration can even be done while the machine is running. This allows a proactive approach without the risk of MMS alarm overrides or unnecessary machine shutdowns.

Vibration transmitters like Bently Nevada 990, Metrix and PVTVM are widely used for machine monitoring. These transmitters feature Buffered Out connectors that can be used for acquiring raw sensor data with our CCM system. To overcome cable length limitations at the Buffered Out connector, our CCM A-100 amplifier can be added to ensure high signal quality transmission up to 75m.

One data acquisition module – many different I/O connections. Whether passive measurement or active supply of the sensor system. The six measurement inputs of each CCM C-421 edge module can be flexibly and individually configured via software, optimizing channel utilization to reduce costs and installation space. This streamlined approach simplifies spare parts management, reducing the need for diverse module stock.

Our commitment to openness is more than a principle; it’s a practice. Beyond supporting standard M2M communication protocols such as OPC UA and Modbus TCP, our data connectors provide seamless data to formats such as Excel CSV, NI TDMS, and Matlab MAT. Moreover, direct API queries provide a streamlined way to access your data directly from the database. Experience full control and access to your data.

As our system is based entirely on web technology, integration into the customer’s IT system is straightforward.

… keine separaten Zugänge ins das OT oder IT Netz.

Lorem ipsum dolor sit amet, consetetur sadipscing elitr, sed diam nonumy eirmod tempor invidunt ut labore et dolore magna aliquyam

Features

??????

Raw data – Save raw data snapshots using time- and event-based triggers including pre- and post-event data

Performing – Intelligent data management scheme for maximum data transfer performance and analysis speed

Analysis – Perform ad-hoc vibration analysis on every snapshot like FFT, Orbit, ISO10816

Purposeful – The Flight Recorder only records relevant machine events, ensuring that no unnecessary data is stored

Multi-Purpose –  6 galvanically isolated multi-purpose analog inputs for proximitors, keyphasors, transmitter & rack Buffered Out connectors  as well as velocity, acceleration, speed & dynamic pressure sensors

Multi-Power  – Each channel can be configured as 2-wire (IEPE 6mA), 3-wire (+24VDC / -24VDC supply) our without power supply.

Multi-Range – Measure sensor data in unipolar range 0 .. ±24V or bipolar range ±24V.

High Quality – 24bit time synchronous sampling @ 100kHz

Small Size – IP20 casing with DIN rail mounting, 45 x 120 x 120mm

Connected – 2x GbE RJ45

Industrial Range – From -20 to +65°C operating temperature @ 10 .. 90% humidity

Optimized – The Gateway ensures high data throughput, storing full-resolution data for around 2 years (typical use), with automatic data reduction at max database capacity.

Trusted – Our METIS software relies on an long-term supported industrial Linux OS from Siemens.

Small Size – Big performance, small footprint. Instead of using big server racks we are using robust IPCs: Small (85 x 85 x 41mm) or Large (191 x 100 x 60mm).

Small Gateway – Quad Atom E3940, 4 GB RAM, 64/128 GB SSD, 2x GbE RJ45, 1x DisplayPort, DIN rail mount

Large Gateway – Quad Celeron N2930, 8 GB RAM, 128/240/480 GB SSD, 2x GbE RJ45, 1x DisplayPort, DIN rail mount

Turbo compressor shaft vibration

Gearbox vibration

Reciprocating compressor vibration

Pump and fan vibration

Housing & bearing vibration

Machine-to-Machine – OPC UA, Modbus TCP, GE Historian Client

Manual Export – JSON, XLS/CSV, NI TDMS, Matlab® MAT

Direct Access – REST API

Expandable – Additional M2M and Export Connectors can be provided on request

Contact

Dr. Rico Schulze
Rico.Schulze@avicomp.com
+49 341 21787 1791

Contact picture Rico Schulze - Kontaktbild Rico Schulze
Contact picture Kevin Schleifer - Kontaktbild Kevin Schleifer

Kevin Schleifer
Kevin.Schleifer@avicomp.com
+49 341 21787 1784