EcoScreen Equipment Analytics Optimizes Plant Availability and Product Quality

IIoT solution monitors paint booth online

2/19/2019

SOUTHFIELD, Mich. - Feb. 19, 2019 – Dürr EcoScreen Equipment Analytics brings transparency and intelligence to paint shop 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 identified and rectified. 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 analyzes all relevant signals from the sensors and actuators integrated in Dürr painting robots. The application technology of the front robot arm, for example, provides data on the pressure regulators, metering pumps and color valves. Main needles, turbine speed, shaping air and air heaters from the electrostatic rotary atomizers are also connected to the data recorder. The software records the positions, torques, and temperatures of the painting and handling robots’ individual axes. Data from the conveyor technology is 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 collected.


Visual representation creates transparency

In addition to the data recorder and database, the IIoT solution comprises a visualization 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 Dürr Systems AG President and CEO Dr. Lars Friedrich. “The detailed information helps to identify and eliminate faults quickly. The cross comparisons of different robots improve root cause analyses and help the plant operator boost plant availability, increase the 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 atomizers can be displayed simultaneously 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 compare bodies by type and color.


Algorithms calculate the ideal plant condition and show anomalies

The “Streaming Analytics” module goes one step further: it analyzes 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 within the plant and in the processes are identified. Employees can initiate corresponding service measures right away and get to the bottom of the deviation before the body 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 intuitive functionality Dürr developed a Model Editor that provides the user with a library of analysis modules. These can also be combined into new models.


For example, the painting pressure data monitored during the application is displayed graphically on the screen. The operator can see that all values are within tolerance and with Streaming Analytics, he can create an analysis model that automatically determines anomalies such as air bubbles in the paint from the characteristics of the signal curve. These possible applications make the Streaming Analytics solution a powerful tool because the software automates the plant operators’ process knowledge using online analyses.


Integration of machine learning in the future

“In parallel with Streaming Analytics, Dürr is developing other modules for batch analytics applications that work on the basis of artificial neural networks. The software learns the optimal process condition automatically and registers every deviation. This means that the software will solve problems through machine learning,” explains Dr. Friedrich. “If the self-learning modules detect trends, problems in the equipment can be identified in advance by specifying a forecast of the event time.”


A number of car manufacturers have been using the EcoScreen Equipment Analytics software since 2018. The additional module Streaming Analytics based on real-time data has been used for the first time in a complete production line since the fourth quarter of 2018. The Batch Analytics module, which uses artificial intelligence, is currently in the trial phase with a customer.


The EcoScreen Equipment Analytics software was developed in Dürr's Digital Factory. In this competence center, founded in early 2018, around 100 software experts are working on solutions for the digitization of production processes.

 

The Dürr Group has been established in the United States since 1970 and currently employs around 880 people. From the new Campus with a state-of-art validation, testing, and training center in Southfield, MI, Dürr USA represents four of the five divisions. Paint and Final Assembly Systems offers equipment for painting and assembly processes, while Application Technology provides paint application systems. Dürr’s Clean Technology Systems is the global leader in air pollution abatement and energy efficient technologies. The subsidiary Schenck Trebel Corporation, based in Deer Park, New York, offers balancing machines, vibration and condition monitoring systems and services for the general industry. The customers of Dürr USA include automotive and commercial vehicle manufacturers as well as their suppliers, and a diverse group of other industries. HOMAG Machinery North America operates the production facilities for HOMAG Group in Grand Rapids, MI, which is also the base for sales and service company Stiles Machinery Inc.

The Dürr Group is one of the world's leading mechanical and plant engineering firms with extensive expertise in automation and digitization/Industry 4.0. Products, systems and services offered by the Group enable highly efficient manufacturing processes in different industries. Dürr supplies sectors like the automotive industry, mechanical engineering, chemical, pharmaceutical and woodworking industries. The Group generated sales of € 3.71 billion in 2017. In October 2018, Dürr acquired the industrial environmental technology business of US-based company Babcock & Wilcox, comprising the MEGTEC and Universal brands. Since then, the company has over 16,000 employees and 108 business locations in 32 countries. The Group operates in the market with five divisions:

  • Paint and Final Assembly Systems: paint shops and final assembly systems for the automotive industry
  • Application Technology: robot technologies for the automated application of paint, sealants and adhesives 
  • Clean Technology Systems: air pollution control systems and noise abatement systems 
  • Measuring and Process Systems: balancing equipment as well as assembly, testing and filling technology
  • Woodworking Machinery and Systems: machinery and equipment for the woodworking industry
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